Thermoformable film

ABSTRACT

A thermoformable film including a polyethylene composition. The polyethylene composition includes a first polyethylene which is an ethylene copolymer having a weight average molecular weight of from 70,000 to 250,000 and a molecular weight distribution M w /M n  of &lt;2.3, a second polyethylene which is an ethylene copolymer or homopolymer having a weight average molecular weight of less than 75,000 and a molecular weight distribution M w /M n  of &lt;2.3, a third polyethylene which is an ethylene copolymer or homopolymer having a weight average molecular weight of less than 75,000 and a molecular weight distribution M w /M n  of &lt;2.3, and a fourth polyethylene which is an ethylene copolymer or homopolymer having a weight average molecular weight of from 100,000 to 250,000 and a molecular weight distribution M w /M n  of &gt;2.3, where the first polyethylene has more short chain branching than the second polyethylene or the third polyethylene. The polyethylene composition has a melt flow ratio (I 21 /I 2 ) of ≤55 and an area Dimensional Thermoformability Index (aDTI) at 105° C. of less than 15.

TECHNICAL FIELD

The present disclosure provides polyethylene compositions which are useful in film thermoforming applications. The polyethylene compositions have a good (i.e. relatively low) area Dimensional Thermoformability Index (aDTI). The polyethylene compositions comprise three polyethylene components which are each made with a single site polymerization catalyst and one polyethylene component which is made with a multi-site polymerization catalyst.

BACKGROUND

Multicomponent polyethylene compositions are well known in the art. One method to access multicomponent polyethylene compositions is to use two or more distinct polymerization catalysts in one or more polymerization reactors. For example, the use of single site and Ziegler-Natta type polymerization catalysts in at least two distinct solution polymerization reactors is known. Such reactors may be configured in series or in parallel.

Solution polymerization processes are generally carried out at temperatures above the melting point of the ethylene homopolymer or copolymer product being made. In a typical solution polymerization process, catalyst components, solvent, monomers and hydrogen are fed under pressure to one or more reactors.

For solution phase ethylene polymerization, or ethylene copolymerization, reactor temperatures can range from about 80° C. to about 300° C. while pressures generally range from about 3 MPag to about 45 MPag. The ethylene homopolymer or copolymer produced remains dissolved in the solvent under reactor conditions. The residence time of the solvent in the reactor is relatively short, for example, from about 1 second to about 20 minutes. The solution process can be operated under a wide range of process conditions that allow the production of a wide variety of ethylene polymers. Post reactor, the polymerization reaction is quenched to prevent further polymerization, by adding a catalyst deactivator, and optionally passivated, by adding an acid scavenger. Once deactivated (and optionally passivated), the polymer solution is passed to a polymer recovery operation (a devolatilization system) where the ethylene homopolymer or copolymer is separated from process solvent, unreacted residual ethylene and unreacted optional α-olefin(s).

Regardless of the manner of production, there remains a need to improve the performance of multicomponent polyethylene compositions in film applications such as the use of such compositions in thermoforming processes. Thermoforming is a process in which a plastic sheet or film is heated to a pliable state under a forming temperature, then stretched into or onto a mold to form a part shape after cooling. Thermoforming can be used to make films into packages for foodstuffs, medicines, or medical and electronic devices.

SUMMARY

An embodiment of the disclosure is a thermoformable film comprising a polyethylene composition comprising:

from 15 to 75 wt. % of a first polyethylene which is an ethylene copolymer, the first polyethylene having a weight average molecular weight M_(W) of from 70,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 5 to 100 short chain branches per thousand carbon atoms;

from 5 to 50 wt. % of a second polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

from 5 to 50 wt. % of a third polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

at least 20 wt. % of a fourth polyethylene which is an ethylene copolymer or an ethylene homopolymer, the fourth polyethylene having a weight average molecular weight M_(W) of from 100,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of >2.3 and from 0 to 75 short chain branches per thousand carbon atoms; wherein

the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)), the third polyethylene (SCB_(PE-3)) and the fourth polyethylene (SCB_(PE-4));

the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)) and the third polyethylene (SCB_(PE-3));

the weight average molecular weight of the second polyethylene and the third polyethylene are less than the weight average molecular weight of the first polyethylene and the fourth polyethylene; and

the weight average molecular weight of the second polyethylene and the third polyethylene are within 20,000 units of each other; wherein,

the polyethylene composition has a density of less than or equal to 0.939 g/cm³, a T_(m) ²−T_(m) ¹ of less than 45° C., a melt index I₂ of from 0.1 to 10 dg/min, and a melt flow ratio, I₂₁/I₂ of less than or equal to 55.

An embodiment of the disclosure is a thermoformable film comprising a polyethylene composition comprising:

from 15 to 75 wt. % of a first polyethylene which is an ethylene copolymer, the first polyethylene having a weight average molecular weight M_(W) of from 70,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 5 to 100 short chain branches per thousand carbon atoms;

from 5 to 50 wt. % of a second polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

from 5 to 50 wt. % of a third polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

at least 20 wt. % of a fourth polyethylene which is an ethylene copolymer or an ethylene homopolymer, the fourth polyethylene having a weight average molecular weight M_(W) of from 100,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of >2.3 and from 0 to 75 short chain branches per thousand carbon atoms; wherein

the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)), the third polyethylene (SCB_(PE-3)) and the fourth polyethylene (SCB_(PE-4));

the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)) and the third polyethylene (SCB_(PE-3));

the weight average molecular weight of the second polyethylene and the third polyethylene are less than the weight average molecular weight of the first polyethylene and the fourth polyethylene; and

the weight average molecular weight of the second polyethylene and the third polyethylene are within 20,000 units of each other; wherein, the polyethylene composition has a density of less than or equal to 0.939 g/cm³, a T_(m) ²−T_(m) ¹ of less than 45° C., a melt index I₂ of from 0.1 to 10 dg/min, a melt flow ratio, I₂₁/I₂ of less than or equal to 55, and an area Dimensional Thermoformability Index (DTI) at 105° C. of less than 15.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the gel permeation chromatographs (GPC) of polyethylene compositions made according to the present disclosure. Differential refractive index detectors were used.

FIG. 2 shows the gel permeation chromatographs with Fourier transform infra-red (GPC-FTIR) detection obtained for polyethylene compositions made according to the present disclosure. The comonomer content, shown as the number of short chain branches per 1000 carbons (y-axis), is given relative to the copolymer molecular weight (x-axis). The upwardly sloping line (from left to right) is the short chain branching (in short chain branches per 1000 carbons atoms) determined by FTIR. As can be seen in the Figure, for Examples 1-3, the number of short chain branches initially increases at higher molecular weights and then decreases again at still higher molecular weights, and hence the comonomer incorporation is said to be “partially reversed” with a peak or maximum present.

FIG. 3 shows the differential scanning calorimetry (DSC) analysis and profile of polyethylene compositions made according to the present disclosure.

FIG. 4 shows a plot of the phase angle (δ) vs. the complex modulus (G*) for polyethylene compositions made according to the present disclosure as well as for some other polyethylenes. The value of the phase angle (δ) at a complex modulus (G*) of 10,000 Pa, is thought to be indicative of the presence of long chain branching in the polyethylene material.

FIG. 5 shows an example in which a plot of time, t (in seconds) vs. transient extensional viscosity, η_(E)*(in Pa.s) is used to determine the average Melt Strain Hardening Index, the “MSHI”.

FIG. 6 shows a diagram which illustrates the planar deformation and the biaxial deformation which occur when a plastic sheet or film is subjected to thermoforming in a mold.

FIG. 7 illustrates the shape and dimensions of a test specimen before and after subjecting the specimen to high temperature tensile experiments. In FIG. 7, “d” is the thickness of the specimen and “W” is the width of the specimen.

FIG. 8 shows the area Dimensional Thermoformability Index (aDTI) values at 95° C., 100° C. and 105° C. for polymers known to have varying levels of performance when used in thermoforming applications: a Nylon polymer, a cyclic olefin copolymer, a linear low density polyethylene copolymer and its blend with a cyclic olefin copolymer; and a high density ethylene homopolymer.

DETAILED DESCRIPTION

Other than in the examples or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, extrusion conditions, etc., used in the specification and claims are to be understood as modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties that the various embodiments desire to obtain. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. The numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

It should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.

All compositional ranges expressed herein are limited in total to and do not exceed 100 percent (volume percent or weight percent) in practice. Where multiple components can be present in a composition, the sum of the maximum amounts of each component can exceed 100 percent, with the understanding that, and as those skilled in the art readily understand, that the amounts of the components actually used will conform to the maximum of 100 percent.

In order to form a more complete understanding of this disclosure the following terms are defined and should be used with the accompanying figures and the description of the various embodiments throughout.

As used herein, the term “monomer” refers to a small molecule that may chemically react and become chemically bonded with itself or other monomers to form a polymer.

As used herein, the term “α-olefin” or “alpha-olefin” is used to describe a monomer having a linear hydrocarbon chain containing from 3 to 20 carbon atoms having a double bond at one end of the chain; an equivalent term is “linear α-olefin”.

As used herein, the term “polyethylene” or “ethylene polymer”, refers to macromolecules produced from ethylene monomers and optionally one or more additional monomers; regardless of the specific catalyst or specific process used to make the ethylene polymer. In the polyethylene art, the one or more additional monomers are called “comonomer(s)” and often include α-olefins. The term “homopolymer” refers to a polymer that contains only one type of monomer. An “ethylene homopolymer” is made using only ethylene as a polymerizable monomer. The term “copolymer” refers to a polymer that contains two or more types of monomer. An “ethylene copolymer” is made using ethylene and one or more other types of polymerizable monomer. Common polyethylenes include high density polyethylene (HDPE), medium density polyethylene (MDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultralow density polyethylene (ULDPE), plastomer and elastomers. The term polyethylene also includes polyethylene terpolymers which may include two or more comonomers in addition to ethylene. The term polyethylene also includes combinations of, or blends of, the polyethylenes described above.

The term “heterogeneously branched polyethylene” refers to a subset of polymers in the ethylene polymer group that are produced using a heterogeneous catalyst system; non-limiting examples of which include Ziegler-Natta or chromium catalysts, both of which are well known in the art.

The term “homogeneously branched polyethylene” refers to a subset of polymers in the ethylene polymer group that are produced using single-site catalysts; non-limiting examples of which include metallocene catalysts, phosphinimine catalysts, and constrained geometry catalysts all of which are well known in the art.

Typically, homogeneously branched polyethylene has narrow molecular weight distributions, for example gel permeation chromatography (GPC) M_(w)/M_(n) values of less than 2.8, especially less than about 2.3, although exceptions may arise; M_(w) and M_(n) refer to weight and number average molecular weights, respectively. In contrast, the M_(w)/M_(n) of heterogeneously branched ethylene polymers are typically greater than the M_(w)/M_(n) of homogeneous polyethylene. In general, homogeneously branched ethylene polymers also have a narrow comonomer distribution, i.e. each macromolecule within the molecular weight distribution has a similar comonomer content. Frequently, the composition distribution breadth index “CDBI” is used to quantify how the comonomer is distributed within an ethylene polymer, as well as to differentiate ethylene polymers produced with different catalysts or processes. The “CDBI₅₀” is defined as the percent of ethylene polymer whose composition is within 50 weight percent (wt. %) of the median comonomer composition; this definition is consistent with that described in WO 93/03093 assigned to Exxon Chemical Patents Inc. The CDB150 of an ethylene interpolymer can be calculated from TREF curves (Temperature Rising Elution Fractionation); the TREF method is described in Wild, et al., J. Polym. Sci., Part B, Polym. Phys., Vol. 20 (3), pages 441-455. Typically, the CDBI₅₀ of homogeneously branched ethylene polymers are greater than about 70% or greater than about 75%. In contrast, the CDBI₅₀ of α-olefin containing heterogeneously branched ethylene polymers are generally lower than the CDBI₅₀ of homogeneous ethylene polymers. For example, the CDBI₅₀ of a heterogeneously branched ethylene polymer may be less than about 75%, or less than about 70%.

It is well known to those skilled in the art, that homogeneously branched ethylene polymers are frequently further subdivided into “linear homogeneous ethylene polymers” and “substantially linear homogeneous ethylene polymers”. These two subgroups differ in the amount of long chain branching: more specifically, linear homogeneous ethylene polymers have less than about 0.01 long chain branches per 1000 carbon atoms; while substantially linear ethylene polymers have greater than about 0.01 to about 3.0 long chain branches per 1000 carbon atoms. A long chain branch is macromolecular in nature, i.e. similar in length to the macromolecule that the long chain branch is attached to. Hereafter, in this disclosure, the term “homogeneously branched polyethylene” or “homogeneously branched ethylene polymer” refers to both linear homogeneous ethylene polymers and substantially linear homogeneous ethylene polymers.

The term “thermoplastic” refers to a polymer that becomes liquid when heated, will flow under pressure and solidify when cooled. Thermoplastic polymers include ethylene polymers as well as other polymers used in the plastic industry; non-limiting examples of other polymers commonly used in film applications include barrier resins (EVOH), tie resins, polyethylene terephthalate (PET), polyam ides and the like.

As used herein the term “monolayer film” refers to a film containing a single layer of one or more thermoplastics.

As used herein, the terms “hydrocarbyl”, “hydrocarbyl radical” or “hydrocarbyl group” refers to linear or cyclic, aliphatic, olefinic, acetylenic and aryl (aromatic) radicals comprising hydrogen and carbon that are deficient by one hydrogen.

As used herein, an “alkyl radical” includes linear, branched and cyclic paraffin radicals that are deficient by one hydrogen radical; non-limiting examples include methyl (—CH₃) and ethyl (—CH₂CH₃) radicals. The term “alkenyl radical” refers to linear, branched and cyclic hydrocarbons containing at least one carbon-carbon double bond that is deficient by one hydrogen radical.

As used herein, the term “aryl” group includes phenyl, naphthyl, pyridyl and other radicals whose molecules have an aromatic ring structure; non-limiting examples include naphthylene, phenanthrene and anthracene. An “arylalkyl” group is an alkyl group having an aryl group pendant there from; non-limiting examples include benzyl, phenethyl and tolylmethyl; an “alkylaryl” is an aryl group having one or more alkyl groups pendant there from; non-limiting examples include tolyl, xylyl, mesityl and cumyl.

As used herein, the phrase “heteroatom” includes any atom other than carbon and hydrogen that can be bound to carbon. A “heteroatom-containing group” is a hydrocarbon radical that contains a heteroatom and may contain one or more of the same or different heteroatoms. In one embodiment, a heteroatom-containing group is a hydrocarbyl group containing from 1 to 3 atoms selected from the group consisting of boron, aluminum, silicon, germanium, nitrogen, phosphorous, oxygen and sulfur. Non-limiting examples of heteroatom-containing groups include radicals of imines, amines, oxides, phosphines, ethers, ketones, oxoazolines heterocyclics, oxazolines, thioethers, and the like. The term “heterocyclic” refers to ring systems having a carbon backbone that comprise from 1 to 3 atoms selected from the group consisting of boron, aluminum, silicon, germanium, nitrogen, phosphorous, oxygen and sulfur.

As used herein the term “unsubstituted” means that hydrogen radicals are bounded to the molecular group that follows the term unsubstituted. The term “substituted” means that the group following this term possesses one or more moieties that have replaced one or more hydrogen radicals in any position within the group; non-limiting examples of moieties include halogen radicals (F, Cl, Br), hydroxyl groups, carbonyl groups, carboxyl groups, amine groups, phosphine groups, alkoxy groups, phenyl groups, naphthyl groups, C₁ to C₃₀ alkyl groups, C₂ to C₃₀ alkenyl groups, and combinations thereof. Non-limiting examples of substituted alkyls and aryls include: acyl radicals, alkylamino radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- and dialkyl-carbamoyl radicals, acyloxy radicals, acylamino radicals, arylamino radicals and combinations thereof.

In the present disclosure, a thermoformable film includes a polyethylene composition and the polyethylene composition includes at least the following types of polymers: a first polyethylene which is an ethylene copolymer and which has a Mw/Mn of less than about 2.3; a second polyethylene which is an ethylene copolymer or an ethylene homopolymer which is different from the first polyethylene and which has a Mw/Mn of less than about 2.3; a third polyethylene which is an ethylene copolymer or an ethylene homopolymer which is different from the first polyethylene and which has a Mw/Mn of less than about 2.3, and a fourth polyethylene which is an ethylene copolymer or an ethylene homopolymer which has a Mw/Mn of greater than about 2.3. Each of these polyethylene components, and the polyethylene composition of which they are each a part are further described below.

The First Polyethylene

In an embodiment of the disclosure, the first polyethylene is made with a single site catalyst, non-limiting examples of which include phosphinimine catalysts, metallocene catalysts, and constrained geometry catalysts, all of which are well known in the art.

In an embodiment of the disclosure, the first polyethylene is an ethylene copolymer. Suitable alpha-olefins which may be copolymerized with ethylene to make an ethylene copolymer include 1-propene, 1-butene, 1-pentene, 1-hexene and 1-octene.

In an embodiment of the disclosure, the first polyethylene is a homogeneously branched ethylene copolymer.

In an embodiment of the disclosure, the first polyethylene is an ethylene/1-octene copolymer.

In an embodiment of the disclosure, the first polyethylene is made with a phosphinimine catalyst.

In an embodiment of the disclosure, a phosphinimine catalyst is represented by formula:

(L^(A))_(a)M(Pl)_(b)(Q)_(n)

wherein (L^(A)) represents is cyclopentadienyl-type ligand; M represents a metal atom selected from the group consisting of Ti, Zr, and Hf; Pl represents a phosphinimine ligand; Q represents an activatable ligand; a is 0 or 1; b is 1 or 2; (a+b)=2; n is 1 or 2, and; the sum of (a+b+n) equals the valance of the metal M.

As used herein, the term “cyclopentadienyl-type” ligand is meant to include ligands which contain at least one five-carbon ring which is bonded to the metal via eta-5 (or in some cases eta-3) bonding. Thus, the term “cyclopentadienyl-type” includes, for example, unsubstituted cyclopentadienyl, singly or multiply substituted cyclopentadienyl, unsubstituted indenyl, singly or multiply substituted indenyl, unsubstituted fluorenyl and singly or multiply substituted fluorenyl. Hydrogenated versions of indenyl and fluorenyl ligands are also contemplated for use in the current disclosure, so long as the five-carbon ring which bonds to the metal via eta-5 (or in some cases eta-3) bonding remains intact. Substituents for a cyclopentadienyl ligand, an indenyl ligand (or hydrogenated version thereof) and a fluorenyl ligand (or hydrogenated version thereof) may be selected from the group consisting of a C1-30 hydrocarbyl radical (which hydrocarbyl radical may be unsubstituted or further substituted by for example a halide and/or a hydrocarbyl group; for example a suitable substituted C1-30 hydrocarbyl radical is a pentafluorobenzyl group such as —CH₂C₆F₅); a halogen atom; a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl or aryloxy radical (each of which may be further substituted by for example a halide and/or a hydrocarbyl group); an amido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a silyl radical of the formula —Si(R′)₃ wherein each R′ is independently selected from the group consisting of hydrogen, a C₁₋₈ alkyl or alkoxy radical, C₆₋₁₀ aryl or aryloxy radicals; and a germanyl radical of the formula —Ge(R′)₃ wherein R′ is as defined directly above.

The phosphinimine ligand, Pl, is defined by formula:

(R^(p))₃P═N—

wherein the R^(p) groups are independently selected from: a hydrogen atom; a halogen atom; C₁₋₂₀ hydrocarbyl radicals which are unsubstituted or substituted with one or more halogen atom(s); a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl radical; a C₆₋₁₀ aryloxy radical; an amido radical; a silyl radical of formula —Si(R^(s))₃, wherein the R^(s) groups are independently selected from, a hydrogen atom, a C₁₋₈ alkyl or alkoxy radical, a C₆₋₁₀ aryl radical, a C₆₋₁₀ aryloxy radical, or a germanyl radical of formula —Ge(R^(G))₃, wherein the R^(G) groups are defined as R^(s) is defined in this paragraph.

In an embodiment of the disclosure, the metal, M in the phosphinimine catalyst is titanium, Ti.

In an embodiment of the disclosure, the single site catalyst used to make the first polyethylene is cyclopentadienyl tri(tertiarybutyl)phosphinimine titanium dichloride, Cp((t-Bu)₃PN)TiCl₂.

In an embodiment of the disclosure, the first polyethylene is made with a metallocene catalyst.

In an embodiment of the disclosure, the first polyethylene is made with a bridged metallocene catalyst.

In an embodiment of the disclosure, the first polyethylene is made with a bridged metallocene catalyst having the formula I:

In Formula (I): M is a group 4 metal selected from titanium, zirconium or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin or lead; R₁ is a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R₂ and R₃ are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R₄ and R₅ are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; and Q is independently an activatable leaving group ligand.

In the current disclosure, the term “activatable”, means that the ligand Q may be cleaved from the metal center M via a protonolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activator compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q may also be transformed into another ligand which is cleaved or abstracted from the metal center M (e.g. a halide may be converted to an alkyl group). Without wishing to be bound by any single theory, protonolysis or abstraction reactions generate an active “cationic” metal center which can polymerize olefins.

In embodiments of the present disclosure, the activatable ligand, Q is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical, and a C₆₋₁₀ aryl or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl, or aryl oxide radicals may be unsubstituted or further substituted by one or more halogen or other group; a C₁₋₈ alkyl; a C₁₋₈ alkoxy; a C₆₋₁₀ aryl or aryloxy; an amido or a phosphido radical, but where Q is not a cyclopentadienyl. Two Q ligands may also be joined to one another and form for example, a substituted or unsubstituted diene ligand (e.g. 1,3-butadiene); or a delocalized heteroatom containing group such as an acetate or acetamidinate group. In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C₁₋₄ alkyl radical and a benzyl radical. Particularly suitable activatable ligands Q are monoanionic such as a halide (e.g. chloride) or a hydrocarbyl (e.g. methyl, benzyl).

In an embodiment of the disclosure, the single site catalyst used to make the first polyethylene is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: [(2,7-tBu₂Flu)Ph₂C(Cp)HfCl₂].

In an embodiment of the disclosure the single site catalyst used to make the first polyethylene has is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula [(2,7-tBu₂Flu)Ph₂C(Cp)HfMe₂].

In addition to the single site catalyst molecule per se, an active single site catalyst system may further include one or more of the following: an alkylaluminoxane co-catalyst and an ionic activator. The single site catalyst system may also optionally include a hindered phenol.

Although the exact structure of alkylaluminoxane is uncertain, subject matter experts generally agree that it is an oligomeric species that contain repeating units of the general formula:

(R)₂AlO—(Al(R)—O)_(n)—Al(R)₂

where the R groups may be the same or different linear, branched or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and n is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) wherein each R group is a methyl radical.

In an embodiment of the disclosure, R of the alkylaluminoxane, is a methyl radical and m is from 10 to 40.

In an embodiment of the disclosure, the co-catalyst is modified methylaluminoxane (MMAO).

It is well known in the art, that the alkylaluminoxane can serve dual roles as both an alkylator and an activator. Hence, an alkylaluminoxane co-catalyst is often used in combination with activatable ligands such as halogens.

In general, ionic activators are comprised of a cation and a bulky anion; wherein the latter is substantially non-coordinating. Non-limiting examples of ionic activators are boron ionic activators that are four coordinate with four ligands bonded to the boron atom. Non-limiting examples of boron ionic activators include the following formulas shown below;

[R⁵]⁺[B(R⁷)₄]⁻

where B represents a boron atom, R⁵ is an aromatic hydrocarbyl (e.g. triphenyl methyl cation) and each R⁷ is independently selected from phenyl radicals which are unsubstituted or substituted with from 3 to 5 substituents selected from fluorine atoms, C1-4 alkyl or alkoxy radicals which are unsubstituted or substituted by fluorine atoms; and a silyl radical of formula —Si(R⁹)₃, where each R⁹ is independently selected from hydrogen atoms and C₁₋₄ alkyl radicals, and

[(R⁸)_(t)ZH]⁺[B(R⁷)₄]⁻

where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R⁸ is selected from C₁₋₈ alkyl radicals, phenyl radicals which are unsubstituted or substituted by up to three C₁₋₄ alkyl radicals, or one R⁸ taken together with the nitrogen atom may form an anilinium radical and R⁷ is as defined above.

In both formula a non-limiting example of R⁷ is a pentafluorophenyl radical. In general, boron ionic activators may be described as salts of tetra(perfluorophenyl) boron; non-limiting examples include anilinium, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl)boron with anilinium and trityl (or triphenylmethylium). Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N-dimethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylanilinium tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropillium tetrakispentafluorophenyl borate, triphenylmethylium tetrakispentafluorophenyl borate, benzene(diazonium)tetrakispentafluorophenyl borate, tropillium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethylium tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropillium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5 tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylanilinium tetrakispentafluorophenyl borate, and triphenylmethylium tetrakispentafluorophenyl borate.

Non-limiting example of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tertiarybutyl-4-ethyl phenol, 4,4′-methylenebis (2,6-di-tertiary-butylphenol), 1,3, 5-trimethyl-2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl) benzene and octadecyl-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl) propionate.

To produce an active single site catalyst system the quantity and mole ratios of the three or four components: the single site catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol are optimized.

In an embodiment of the disclosure, the single site catalyst used to make the first polyethylene produces no long chain branches, and the first polyethylene will contain no measurable amounts of long chain branches.

In an embodiment of the disclosure, the single site catalyst used to make the first polyethylene produces long chain branches, and the first polyethylene will contain long chain branches, hereinafter ‘LCB’. LCB is a well-known structural phenomenon in polyethylenes and well known to those of ordinary skill in the art. Traditionally, there are three methods for LCB analysis, namely, nuclear magnetic resonance spectroscopy (NMR), for example see J. C. Randall, J Macromol. Sci., Rev. Macromol. Chem. Phys. 1989, 29, 201; triple detection SEC equipped with a DRI, a viscometer and a low-angle laser light scattering detector, for example see W. W. Yau and D. R. Hill, Int. J. Polym. Anal. Charact. 1996; 2:151; and rheology, for example see W. W. Graessley, Acc. Chem. Res. 1977, 10, 332-339. In this disclosure, a long chain branch is macromolecular in nature, i.e. long enough to be seen in an NMR spectra, triple detector SEC experiments or rheological experiments.

In embodiments of the disclosure, the upper limit on the molecular weight distribution, M_(w)/M_(n) of the first polyethylene may be about 2.8, or about 2.5, or about 2.4, or about 2.3, or about 2.2. In embodiments of the disclosure, the lower limit on the molecular weight distribution, M_(w)/M_(n) of the first polyethylene may be about 1.4, or about 1.6, or about 1.7, or about 1.8, or about 1.9.

In embodiments of the disclosure, the first polyethylene has a molecular weight distribution, M_(w)/M_(n) of <2.3, or <2.1, or <2.0 or about 2.0. In embodiments of the disclosure, the first polyethylene has a molecular weight distribution, M_(w)/M_(n) of from about 1.7 to about 2.2.

In an embodiment of the disclosure, the first polyethylene has from 1 to 200 short chain branches per thousand carbon atoms (SCB_(PE-1)). In further embodiments, the first polyethylene has from 3 to 150 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 5 to 100 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 10 to 100 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 5 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 10 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 15 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 20 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)). In still further embodiments, the first polyethylene has from 20 to 100 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 100 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 80 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 30 to 100 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 30 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 75 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 60 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 50 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 30 to 60 short chain branches per thousand carbon atoms (SCB_(PE-1)), or from 25 to 55 short chain branches per thousand carbon atoms (SCB_(PE-1)).

The short chain branching (i.e. the short chain branching per thousand carbons, SCB_(PE-1)) is the branching due to the presence of an alpha-olefin comonomer in the polyethylene and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc.

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)), is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)), is greater than the number of short chain branches per thousand carbon atoms in the third polyethylene (SCB_(PE-3)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)), is greater than the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)), is greater than the number of short chain branches per thousand carbon atoms in each of the second polyethylene (SCB_(PE-2)), and the third polyethylene (SCB_(PE-3)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)), is greater than the number of short chain branches per thousand carbon atoms in each of the second polyethylene (SCB_(PE-2)), the third polyethylene (SCB_(PE-3)) and the fourth polyethylene (SCB_(PE-4)).

In embodiments of the disclosure, the upper limit on the density, d1 of the first polyethylene may be about 0.975 g/cm³; in some cases, about 0.965 g/cm³ and, in other cases about 0.955 g/cm³. In embodiments of the disclosure, the lower limit on the density, d1 of the first polyethylene may be about 0.855 g/cm³, in some cases about 0.865 g/cm³, and, in other cases about 0.875 g/cm³.

In embodiments of the disclosure the density, d1 of the first polyethylene may be from about 0.855 to about 0.965 g/cm³, or from about 0.865 g/cm³ to about 0.965 g/cm³, or from about 0.870 g/cm³ to about 0.960 g/cm³, or from about 0.865 g/cm³ to about 0.950 g/cm³, or from about 0.865 g/cm³ to about 0.940 g/cm³, or from about 0.865 g/cm³ to about 0.936 g/cm³, or from about 0.860 g/cm³ to about 0.932 g/cm³, or from about 0.865 g/cm³ to about 0.926 g/cm³, or from about 0.865 g/cm³ to about 0.921 g/cm³, or from about 0.865 g/cm³ to about 0.918 g/cm³, or from about 0.865 g/cm³ to about 0.916 g/cm³, or from about 0.870 g/cm³ to about 0.916 g/cm³, or from about 0.865 g/cm³ to about 0.912 g/cm³, or from about 0.865 g/cm³ to about 0.910 g/cm³, or from about 0.865 g/cm³ to about 0.905 g/cm³, or from about 0.865 g/cm³ to about 0.900 g/cm³, or from about 0.855 g/cm³ to about 0.900 g/cm³, or from about 0.855 g/cm³ to about 0.905 g/cm³, or from about 0.855 g/cm³ to about 0.910 g/cm³, or from about 0.855 g/cm³ to about 0.916 g/cm³.

In embodiments of the disclosure, the upper limit on the CDBI₅₀ of the first polyethylene may be about 98 weight %, in other cases about 95 wt. % and in still other cases about 90 wt. %. In embodiments of the disclosure, the lower limit on the CDBI₅₀ of the first polyethylene may be about 70 weight %, in other cases about 75 wt. % and in still other cases about 80 wt. %.

In embodiments of the disclosure the melt index of the first polyethylene I₂ ¹ may be from about 0.01 dg/min to about 1000 dg/min, or from about 0.01 dg/min to about 500 dg/min, or from about 0.01 dg/min to about 100 dg/min, or from about 0.01 dg/min to about 50 dg/min, or from about 0.01 dg/min to about 25 dg/min, or from about 0.01 dg/min to about 10 dg/min, or from about 0.01 dg/min to about 5 dg/min, or from about 0.01 dg/min to about 3 dg/min, or from about 0.01 dg/min to about 1 dg/min, or less than about 5 dg/min, or less than about 3 dg/min, or less than about 1.0 dg/min, or less than about 0.75 dg/min.

In an embodiment of the disclosure, the first polyethylene has a weight average molecular weight, M_(w) of from about 50,000 to about 300,000, or from about 50,000 to about 250,000, or from about 60,000 to about 250,000, or from about 70,000 to about 250,000 or from about 60,000 to about 220,000, or from about 70,000 to about 200,000, or from about 75,000 to about 200,000, or from about 75,000 to about 195,000, or from about 75,000 to about 190,000, or from about 75,000 to about 175,000; or from about 70,000 to about 175,000, or from about 70,000 to about 150,000.

In an embodiment of the disclosure, the first polyethylene has a weight average molecular weight, M_(w) which is greater than the weight average molecular weight, M_(w) of the second polyethylene.

In an embodiment of the disclosure, the first polyethylene has a weight average molecular weight, M_(w) which is greater than the weight average molecular weight, M_(w) of the third polyethylene.

In an embodiment of the disclosure, the first polyethylene has a weight average molecular weight, M_(w) which is greater than the weight average molecular weight, M_(w) of both the second polyethylene and the third polyethylene.

In embodiments of the disclosure, the upper limit on the weight percent (wt %) of the first polyethylene in the polyethylene composition (i.e. the weight percent of the first polyethylene based on the total weight of the first, the second, the third and the fourth polyethylene) may be about 80 wt. %, or about 75 wt. %, or about 70 wt. %, or about 65 wt. %, or about 60 wt. %, or about 55 wt. % or about 50 wt. %, or about 45 wt. %, or about 40 wt. %, or about 35 wt. %. In embodiments of the disclosure, the lower limit on the wt. % of the first polyethylene in the polyethylene composition may be about 1 wt. %, or about 5 wt. %, or about 10 wt. %, or about 15 wt. %, or about 20 wt. %, or about 25 wt. % or in other cases about 30 wt. %.

The Second Polyethylene

In an embodiment of the disclosure, the second polyethylene is made with a single site catalyst, non-limiting examples of which include phosphinimine catalysts, metallocene catalysts, and constrained geometry catalysts, all of which are well known in the art.

In an embodiment of the disclosure, the second polyethylene is an ethylene homopolymer.

In an embodiment of the disclosure, the second polyethylene is an ethylene copolymer. Suitable alpha-olefins which may be copolymerized with ethylene to make an ethylene copolymer include 1-propene, 1-butene, 1-pentene, 1-hexene and 1-octene.

In an embodiment of the disclosure, the second polyethylene is a homogeneously branched ethylene copolymer.

In an embodiment of the disclosure, the second polyethylene is an ethylene/1-octene copolymer.

In an embodiment of the disclosure, the second polyethylene is made with a phosphinimine catalyst.

In an embodiment of the disclosure, a phosphinimine catalyst is represented by formula:

(L^(A))_(a)M(Pl)_(b)(Q)_(n)

wherein (L^(A)) represents is cyclopentadienyl-type ligand; M represents a metal atom selected from the group consisting of Ti, Zr, and Hf; Pl represents a phosphinimine ligand; Q represents an activatable ligand; a is 0 or 1; b is 1 or 2; (a+b)=2; n is 1 or 2, and; the sum of (a+b+n) equals the valance of the metal M.

As used herein, the term “cyclopentadienyl-type” ligand is meant to include ligands which contain at least one five-carbon ring which is bonded to the metal via eta-5 (or in some cases eta-3) bonding. Thus, the term “cyclopentadienyl-type” includes, for example, unsubstituted cyclopentadienyl, singly or multiply substituted cyclopentadienyl, unsubstituted indenyl, singly or multiply substituted indenyl, unsubstituted fluorenyl and singly or multiply substituted fluorenyl. Hydrogenated versions of indenyl and fluorenyl ligands are also contemplated for use in the current disclosure, so long as the five-carbon ring which bonds to the metal via eta-5 (or in some cases eta-3) bonding remains intact. Substituents for a cyclopentadienyl ligand, an indenyl ligand (or hydrogenated version thereof) and a fluorenyl ligand (or hydrogenated version thereof) may be selected from the group consisting of a C₁₋₃₀ hydrocarbyl radical (which hydrocarbyl radical may be unsubstituted or further substituted by for example a halide and/or a hydrocarbyl group; for example a suitable substituted C₁₋₃₀ hydrocarbyl radical is a pentafluorobenzyl group such as —CH₂C₆F₅); a halogen atom; a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl or aryloxy radical (each of which may be further substituted by for example a halide and/or a hydrocarbyl group); an amido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a silyl radical of the formula —Si(R′)₃ wherein each R′ is independently selected from the group consisting of hydrogen, a C₁₋₈ alkyl or alkoxy radical, C₆₋₁₀ aryl or aryloxy radicals; and a germanyl radical of the formula —Ge(R′)₃ wherein R′ is as defined directly above.

The phosphinimine ligand, Pl, is defined by formula:

(R^(p))₃P═N—

wherein the R^(p) groups are independently selected from: a hydrogen atom; a halogen atom; C₁₋₂₀ hydrocarbyl radicals which are unsubstituted or substituted with one or more halogen atom(s); a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl radical; a C₆₋₁₀ aryloxy radical; an amido radical; a silyl radical of formula —Si(R^(s))₃, wherein the R^(s) groups are independently selected from, a hydrogen atom, a C₁₋₈ alkyl or alkoxy radical, a C₆₋₁₀ aryl radical, a C₆₋₁₀ aryloxy radical, or a germanyl radical of formula —Ge(R^(G))₃, wherein the R^(G) groups are defined as R^(s) is defined in this paragraph.

In an embodiment of the disclosure, the metal, M in the phosphinimine catalyst is titanium, Ti.

In an embodiment of the disclosure, the single site catalyst used to make the second polyethylene is cyclopentadienyl tri(tertiarybutyl)phosphinimine titanium dichloride, Cp((t-Bu)₃PN)TiCl₂.

In an embodiment of the disclosure, the second polyethylene is made with a metallocene catalyst.

In an embodiment of the disclosure, the second polyethylene is made with a bridged metallocene catalyst.

In an embodiment of the disclosure, the second polyethylene is made with a bridged metallocene catalyst having the formula I:

In Formula (I): M is a group 4 metal selected from titanium, zirconium or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin or lead; R₁ is a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; and Q is independently an activatable leaving group ligand.

In the current disclosure, the term “activatable”, means that the ligand Q may be cleaved from the metal center M via a protonolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activator compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q may also be transformed into another ligand which is cleaved or abstracted from the metal center M (e.g. a halide may be converted to an alkyl group). Without wishing to be bound by any single theory, protonolysis or abstraction reactions generate an active “cationic” metal center which can polymerize olefins.

In embodiments of the present disclosure, the activatable ligand, Q is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical, and a C₆₋₁₀ aryl or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl, or aryl oxide radicals may be unsubstituted or further substituted by one or more halogen or other group; a C₁₋₈ alkyl; a C₁₋₈ alkoxy; a C₆₋₁₀ aryl or aryloxy; an amido or a phosphido radical, but where Q is not a cyclopentadienyl. Two Q ligands may also be joined to one another and form for example, a substituted or unsubstituted diene ligand (e.g. 1,3-butadiene); or a delocalized heteroatom containing group such as an acetate or acetamidinate group. In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C₁₋₄ alkyl radical and a benzyl radical. Particularly suitable activatable ligands Q are monoanionic such as a halide (e.g. chloride) or a hydrocarbyl (e.g. methyl, benzyl).

In an embodiment of the disclosure, the single site catalyst used to make the second polyethylene is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: [(2,7-tBu₂Flu)Ph₂C(Cp)HfCl₂].

In an embodiment of the disclosure the single site catalyst used to make the second polyethylene has is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula [(2,7-tBu₂Flu)Ph₂C(Cp)HfMe₂].

In addition to the single site catalyst molecule per se, an active single site catalyst system may further include one or more of the following: an alkylaluminoxane co-catalyst and an ionic activator. The single site catalyst system may also optionally include a hindered phenol.

Although the exact structure of alkylaluminoxane is uncertain, subject matter experts generally agree that it is an oligomeric species that contain repeating units of the general formula:

(R)₂AlO—(Al(R)—O)_(n)—Al(R)₂

where the R groups may be the same or different linear, branched or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and n is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) wherein each R group is a methyl radical.

In an embodiment of the disclosure, R of the alkylaluminoxane, is a methyl radical and m is from 10 to 40.

In an embodiment of the disclosure, the co-catalyst is modified methylaluminoxane (MMAO).

It is well known in the art, that the alkylaluminoxane can serve dual roles as both an alkylator and an activator. Hence, an alkylaluminoxane co-catalyst is often used in combination with activatable ligands such as halogens.

In general, ionic activators are comprised of a cation and a bulky anion; wherein the latter is substantially non-coordinating. Non-limiting examples of ionic activators are boron ionic activators that are four coordinate with four ligands bonded to the boron atom. Non-limiting examples of boron ionic activators include the following formulas shown below;

[R⁵]⁺[B(R⁷)₄]⁻

where B represents a boron atom, R⁵ is an aromatic hydrocarbyl (e.g. triphenyl methyl cation) and each R⁷ is independently selected from phenyl radicals which are unsubstituted or substituted with from 3 to 5 substituents selected from fluorine atoms, C₁₋₄ alkyl or alkoxy radicals which are unsubstituted or substituted by fluorine atoms; and a silyl radical of formula —Si(R⁹)₃, where each R⁹ is independently selected from hydrogen atoms and C₁₋₄ alkyl radicals, and

[(R⁸)_(t)ZH]⁺[B(R⁷)₄]⁻

where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R⁸ is selected from C₁₋₈ alkyl radicals, phenyl radicals which are unsubstituted or substituted by up to three C₁₋₄ alkyl radicals, or one R⁸ taken together with the nitrogen atom may form an anilinium radical and R⁷ is as defined above.

In both formula a non-limiting example of R⁷ is a pentafluorophenyl radical. In general, boron ionic activators may be described as salts of tetra(perfluorophenyl) boron; non-limiting examples include anilinium, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl)boron with anilinium and trityl (or triphenylmethylium). Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N-dimethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylanilinium tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropillium tetrakispentafluorophenyl borate, triphenylmethylium tetrakispentafluorophenyl borate, benzene(diazonium)tetrakispentafluorophenyl borate, tropillium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethylium tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropillium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5 tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylanilinium tetrakispentafluorophenyl borate, and triphenylmethylium tetrakispentafluorophenyl borate.

Non-limiting example of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tertiarybutyl-4-ethyl phenol, 4,4′-methylenebis (2,6-di-tertiary-butylphenol), 1,3, 5-trimethyl-2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl) benzene and octadecyl-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl) propionate.

To produce an active single site catalyst system the quantity and mole ratios of the three or four components: the single site catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol are optimized.

In an embodiment of the disclosure, the single site catalyst used to make the second polyethylene produces no long chain branches, and the second polyethylene will contain no measurable amounts of long chain branches.

In an embodiment of the disclosure, the single site catalyst used to make the second polyethylene produces long chain branches, and the second polyethylene will contain long chain branches, hereinafter ‘LCB’. LCB is a well-known structural phenomenon in polyethylenes and well known to those of ordinary skill in the art. Traditionally, there are three methods for LCB analysis, namely, nuclear magnetic resonance spectroscopy (NMR), for example see J. C. Randall, J Macromol. Sci., Rev. Macromol. Chem. Phys. 1989, 29, 201; triple detection SEC equipped with a DRI, a viscometer and a low-angle laser light scattering detector, for example see W. W. Yau and D. R. Hill, Int. J. Polym. Anal. Charact. 1996; 2:151; and rheology, for example see W. W. Graessley, Acc. Chem. Res. 1977, 10, 332-339. In this disclosure, a long chain branch is macromolecular in nature, i.e. long enough to be seen in an NMR spectra, triple detector SEC experiments or rheological experiments.

In embodiments of the disclosure, the upper limit on the molecular weight distribution, M_(w)/M_(n) of the second polyethylene may be about 2.8, or about 2.5, or about 2.4, or about 2.3, or about 2.2. In embodiments of the disclosure, the lower limit on the molecular weight distribution, M_(w)/M_(n) of the second polyethylene may be about 1.4, or about 1.6, or about 1.7, or about 1.8, or about 1.9.

In embodiments of the disclosure, the second polyethylene has a molecular weight distribution, M_(w)/M_(n) of <2.3, or <2.1, or <2.0 or about 2.0. In embodiments of the disclosure, the second polyethylene has a molecular weight distribution, M_(w)/M_(n) of from about 1.7 to about 2.2.

In an embodiment of the disclosure, the second polyethylene has from 0 to 100 short chain branches per thousand carbon atoms (SCB_(PE-2)). In further embodiments, the second polyethylene has from 0 to 30 short chain branches per thousand carbon atoms (SCB_(PE-2)), or from 0 to 20 short chain branches per thousand carbon atoms (SCB_(PE-2)), or from 0 to 15 short chain branches per thousand carbon atoms (SCB_(PE-2)), or from 0 to 10 short chain branches per thousand carbon atoms (SCB_(PE-2)), or from 0 to 5 short chain branches per thousand carbon atoms (SCB_(PE-2)), or fewer than 5 short chain branches per thousand carbon atoms (SCB_(PE-2)), or fewer than 3 short chain branches per thousand carbon atoms (SCB_(PE-2)), or fewer than 1 short chain branches per thousand carbon atoms (SCB_(PE-2)), or about zero short chain branches per thousand carbon atoms (SCB_(PE-2)).

The short chain branching (i.e. the short chain branching per thousand carbons, SCB_(PE-2)) is the branching due to the presence of an alpha-olefin comonomer in the polyethylene and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc.

In embodiments of the disclosure, the upper limit on the density, d2 of the second polyethylene may be about 0.985 g/cm³; in some cases, about 0.975 g/cm³ and, in other cases about 0.965 g/cm³. In embodiments of the disclosure, the lower limit on the density, d2 of the second polyethylene may be about 0.921 g/cm³, in some cases about 0.932 g/cm³, and, in other cases about 0.949 g/cm³.

In embodiments of the disclosure the density, d2 of the second polyethylene may be from about 0.921 g/cm³ to about 0.980 g/cm³, or from about 0.921 g/cm³ to about 0.975 g/cm³, or from about 0.926 g/cm³ to about 0.975 g/cm³, or from about 0.930 g/cm³ to about 0.975 g/cm³, or from about 0.936 g/cm³ to about 0.975 g/cm³, or from about 0.940 g/cm³ to about 0.975 g/cm³, or from about 0.940 g/cm³ to about 0.980 g/cm³, or from about 0.945 g/cm³ to about 0.975 g/cm³, or from about 0.950 g/cm³ to about 0.975 g/cm³, or from about 0.951 g/cm³ to about 0.975 g/cm³, or from about 0.953 g/cm³ to about 0.975 g/cm³, or from about 0.953 g/cm³ to about 0.985 g/cm³.

In embodiments of the disclosure the melt index of the second polyethylene I₂ ² may be from about 0.1 dg/min to about 10000 dg/min, or from about 0.1 dg/min to about 5000 dg/min, or from about 1 dg/min to about 10000 dg/min, or from about 1 dg/min to about 5000 dg/min, or from about 1 dg/min to about 2500 dg/min, or from about 1 dg/min to about 2000 dg/min, or from about 10 dg/min to about 10000 dg/min, or from about 10 dg/min to about 5000 dg/min, or from about 10 dg/min to about 2500 dg/min, or from about 25 dg/min to about 10000 dg/min, or from about 25 dg/min to about 5000 dg/min, or from about 25 dg/min to about 2500 dg/min.

In an embodiment of the disclosure, the second polyethylene has a weight average molecular weight, M_(w) of from about 10,000 to about 150,000, or from about 10,000 to about 125,000, or from about 15,000 to about 100,000, or from about 15,000 to about 90,000, or from about 15,000 to about 80,000 or from about 20,000 to about 75,000, or from about 20,000 to about 90,000, or from about 20,000 to about 80,000, or from about 15,000 to about 75,000, or from about 10,000 to about 50,000, or from about 15,000 to about 40,000, or from about 12,000 to about 45,000, or from about 12,000 to about 40,000, or less than about 100,000 or less than about 75,000, or less than about 50,000, or less than about 45,000 or less than about 40,000, or less than about 35,000, or less than about 30,000.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene is less than the weight average molecular weight of the first polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene is less than the weight average molecular weight of the fourth polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene is less than the weight average molecular weight of the first polyethylene and the fourth polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 25,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 20,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 15,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 10,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 7,500 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 5,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the second polyethylene and the third polyethylene are within 2,500 units (in g/mol) of each other.

In embodiments of the disclosure, the upper limit on the weight percent (wt. %) of the second polyethylene in the polyethylene composition (i.e. the weight percent of the second polyethylene based on the total weight of the first, the second, the third and the fourth polyethylene) may be about 75 wt. %, or about 70 wt. %, or about 65 wt. %, or about 60 wt. %, or about 55 wt. %, or about 50 wt. %, or about 45 wt. %, or about 40 wt. % or about 35 wt. %. In embodiments of the disclosure, the lower limit on the wt. % of the second polyethylene in the polyethylene composition may be about 1 wt. %, or 5 wt. %, or about 10 wt. %, or about 15 wt. %, or about 20 wt. %.

The Third Polyethylene

In an embodiment of the disclosure, the third polyethylene is made with a single site catalyst, non-limiting examples of which include phosphinimine catalysts, metallocene catalysts, and constrained geometry catalysts, all of which are well known in the art.

In an embodiment of the disclosure, the third polyethylene is an ethylene homopolymer.

In an embodiment of the disclosure, the third polyethylene is an ethylene copolymer. Suitable alpha-olefins which may be copolymerized with ethylene to make an ethylene copolymer include 1-propene, 1-butene, 1-pentene, 1-hexene and 1-octene.

In an embodiment of the disclosure, the third polyethylene is a homogeneously branched ethylene copolymer.

In an embodiment of the disclosure, the third polyethylene is an ethylene/1-octene copolymer.

In an embodiment of the disclosure, the third polyethylene is made with a phosphinimine catalyst.

In an embodiment of the disclosure, a phosphinimine catalyst is represented by formula:

(L^(A))_(a)M(Pl)_(b)(Q)_(n)

wherein (L^(A)) represents is cyclopentadienyl-type ligand; M represents a metal atom selected from the group consisting of Ti, Zr, and Hf; Pl represents a phosphinimine ligand; Q represents an activatable ligand; a is 0 or 1; b is 1 or 2; (a+b)=2; n is 1 or 2, and; the sum of (a+b+n) equals the valance of the metal M.

As used herein, the term “cyclopentadienyl-type” ligand is meant to include ligands which contain at least one five-carbon ring which is bonded to the metal via eta-5 (or in some cases eta-3) bonding. Thus, the term “cyclopentadienyl-type” includes, for example, unsubstituted cyclopentadienyl, singly or multiply substituted cyclopentadienyl, unsubstituted indenyl, singly or multiply substituted indenyl, unsubstituted fluorenyl and singly or multiply substituted fluorenyl. Hydrogenated versions of indenyl and fluorenyl ligands are also contemplated for use in the current disclosure, so long as the five-carbon ring which bonds to the metal via eta-5 (or in some cases eta-3) bonding remains intact. Substituents for a cyclopentadienyl ligand, an indenyl ligand (or hydrogenated version thereof) and a fluorenyl ligand (or hydrogenated version thereof) may be selected from the group consisting of a C₁₋₃₀ hydrocarbyl radical (which hydrocarbyl radical may be unsubstituted or further substituted by for example a halide and/or a hydrocarbyl group; for example a suitable substituted C₁₋₃₀ hydrocarbyl radical is a pentafluorobenzyl group such as —CH₂C₆F₅); a halogen atom; a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl or aryloxy radical (each of which may be further substituted by for example a halide and/or a hydrocarbyl group); an amido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C₁₋₈ alkyl radicals; a silyl radical of the formula —Si(R′)₃ wherein each R′ is independently selected from the group consisting of hydrogen, a C₁₋₈ alkyl or alkoxy radical, C₆₋₁₀ aryl or aryloxy radicals; and a germanyl radical of the formula —Ge(R′)₃ wherein R′ is as defined directly above.

The phosphinimine ligand, Pl, is defined by formula:

(R^(p))₃P═N—

wherein the R^(p) groups are independently selected from: a hydrogen atom; a halogen atom; C₁₋₂₀ hydrocarbyl radicals which are unsubstituted or substituted with one or more halogen atom(s); a C₁₋₈ alkoxy radical; a C₆₋₁₀ aryl radical; a C₆₋₁₀ aryloxy radical; an amido radical; a silyl radical of formula —Si(R^(s))₃, wherein the R^(s) groups are independently selected from, a hydrogen atom, a C₁₋₈ alkyl or alkoxy radical, a C₆₋₁₀ aryl radical, a C₆₋₁₀ aryloxy radical, or a germanyl radical of formula —Ge(R^(G))₃, wherein the R^(G) groups are defined as R^(s) is defined in this paragraph.

In an embodiment of the disclosure, the metal, M in the phosphinimine catalyst is titanium, Ti.

In an embodiment of the disclosure, the single site catalyst used to make the third polyethylene is cyclopentadienyl tri(tertiarybutyl)phosphinimine titanium dichloride, Cp((t-Bu)₃PN)TiCl₂.

In an embodiment of the disclosure, the third polyethylene is made with a metallocene catalyst.

In an embodiment of the disclosure, the third polyethylene is made with a bridged metallocene catalyst.

In an embodiment of the disclosure, the third polyethylene is made with a bridged metallocene catalyst having the formula I:

In Formula (I): M is a group 4 metal selected from titanium, zirconium or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin or lead; R₁ is a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R₂ and R₃ are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; R₄ and R₅ are independently selected from a hydrogen atom, a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical or a C₆₋₁₀ aryl oxide radical; and Q is independently an activatable leaving group ligand.

In the current disclosure, the term “activatable”, means that the ligand Q may be cleaved from the metal center M via a protonolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activator compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q may also be transformed into another ligand which is cleaved or abstracted from the metal center M (e.g. a halide may be converted to an alkyl group). Without wishing to be bound by any single theory, protonolysis or abstraction reactions generate an active “cationic” metal center which can polymerize olefins.

In embodiments of the present disclosure, the activatable ligand, Q is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C₁₋₂₀ hydrocarbyl radical, a C₁₋₂₀ alkoxy radical, and a C₆₋₁₀ aryl or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl, or aryl oxide radicals may be unsubstituted or further substituted by one or more halogen or other group; a C₁₋₈ alkyl; a C₁₋₈ alkoxy; a C₆₋₁₀ aryl or aryloxy; an amido or a phosphido radical, but where Q is not a cyclopentadienyl. Two Q ligands may also be joined to one another and form for example, a substituted or unsubstituted diene ligand (e.g. 1,3-butadiene); or a delocalized heteroatom containing group such as an acetate or acetamidinate group. In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C₁₋₄ alkyl radical and a benzyl radical. Particularly suitable activatable ligands Q are monoanionic such as a halide (e.g. chloride) or a hydrocarbyl (e.g. methyl, benzyl).

In an embodiment of the disclosure, the single site catalyst used to make the third polyethylene is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: [(2,7-tBu₂Flu)Ph₂C(Cp)HfCl₂].

In an embodiment of the disclosure the single site catalyst used to make the third polyethylene has is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula [(2,7-tBu₂Flu)Ph₂C(Cp)HfMe₂].

In addition to the single site catalyst molecule per se, an active single site catalyst system may further include one or more of the following: an alkylaluminoxane co-catalyst and an ionic activator. The single site catalyst system may also optionally include a hindered phenol.

Although the exact structure of alkylaluminoxane is uncertain, subject matter experts generally agree that it is an oligomeric species that contain repeating units of the general formula:

(R)₂AlO—(Al(R)—O)_(n)—Al(R)₂

where the R groups may be the same or different linear, branched or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and n is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) wherein each R group is a methyl radical.

In an embodiment of the disclosure, R of the alkylaluminoxane, is a methyl radical and m is from 10 to 40.

In an embodiment of the disclosure, the co-catalyst is modified methylaluminoxane (MMAO).

It is well known in the art, that the alkylaluminoxane can serve dual roles as both an alkylator and an activator. Hence, an alkylaluminoxane co-catalyst is often used in combination with activatable ligands such as halogens.

In general, ionic activators are comprised of a cation and a bulky anion; wherein the latter is substantially non-coordinating. Non-limiting examples of ionic activators are boron ionic activators that are four coordinate with four ligands bonded to the boron atom. Non-limiting examples of boron ionic activators include the following formulas shown below;

[R⁵]⁺[B(R⁷)₄]⁻

where B represents a boron atom, R⁵ is an aromatic hydrocarbyl (e.g. triphenyl methyl cation) and each R⁷ is independently selected from phenyl radicals which are unsubstituted or substituted with from 3 to 5 substituents selected from fluorine atoms, C₁₋₄ alkyl or alkoxy radicals which are unsubstituted or substituted by fluorine atoms; and a silyl radical of formula —Si(R⁹)₃, where each R⁹ is independently selected from hydrogen atoms and C₁₋₄ alkyl radicals, and

[(R⁸)_(t)ZH]⁺[B(R⁷)₄]⁻

where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R⁸ is selected from C₁₋₈ alkyl radicals, phenyl radicals which are unsubstituted or substituted by up to three C₁₋₄ alkyl radicals, or one R⁸ taken together with the nitrogen atom may form an anilinium radical and R⁷ is as defined above.

In both formula a non-limiting example of R⁷ is a pentafluorophenyl radical. In general, boron ionic activators may be described as salts of tetra(perfluorophenyl) boron; non-limiting examples include anilinium, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl)boron with anilinium and trityl (or triphenylmethylium). Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N-dimethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)boron, N,N-diethylanilinium tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylanilinium tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropillium tetrakispentafluorophenyl borate, triphenylmethylium tetrakispentafluorophenyl borate, benzene(diazonium)tetrakispentafluorophenyl borate, tropillium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropillium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethylium tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropillium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5 tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylanilinium tetrakispentafluorophenyl borate, and triphenylmethylium tetrakispentafluorophenyl borate.

Non-limiting example of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tertiarybutyl-4-ethyl phenol, 4,4′-methylenebis (2,6-di-tertiary-butylphenol), 1,3, 5-trimethyl-2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl) benzene and octadecyl-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl) propionate.

To produce an active single site catalyst system the quantity and mole ratios of the three or four components: the single site catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol are optimized.

In an embodiment of the disclosure, the single site catalyst used to make the third polyethylene produces no long chain branches, and the third polyethylene will contain no measurable amounts of long chain branches.

In an embodiment of the disclosure, the single site catalyst used to make the third polyethylene produces long chain branches, and the third polyethylene will contain long chain branches, hereinafter ‘LCB’. LCB is a well-known structural phenomenon in polyethylenes and well known to those of ordinary skill in the art. Traditionally, there are three methods for LCB analysis, namely, nuclear magnetic resonance spectroscopy (NMR), for example see J. C. Randall, J Macromol. Sci., Rev. Macromol. Chem. Phys. 1989, 29, 201; triple detection SEC equipped with a DRI, a viscometer and a low-angle laser light scattering detector, for example see W. W. Yau and D. R. Hill, Int. J. Polym. Anal. Charact. 1996; 2:151; and rheology, for example see W. W. Graessley, Acc. Chem. Res. 1977, 10, 332-339. In this disclosure, a long chain branch is macromolecular in nature, i.e. long enough to be seen in an NMR spectra, triple detector SEC experiments or rheological experiments.

In embodiments of the disclosure, the upper limit on the molecular weight distribution, M_(w)/M_(n) of the third polyethylene may be about 2.8, or about 2.5, or about 2.4, or about 2.3, or about 2.2. In embodiments of the disclosure, the lower limit on the molecular weight distribution, M_(w)/M_(n) of the third polyethylene may be about 1.4, or about 1.6, or about 1.7, or about 1.8, or about 1.9.

In embodiments of the disclosure, the third polyethylene has a molecular weight distribution, M_(w)/M_(n) of <2.3, or <2.1, or <2.0 or about 2.0. In embodiments of the disclosure, the third polyethylene has a molecular weight distribution, M_(w)/M_(n) of from about 1.7 to about 2.2.

In an embodiment of the disclosure, the third polyethylene has from 0 to 100 short chain branches per thousand carbon atoms (SCB_(PE-3)). In further embodiments, the third polyethylene has from 0 to 30 short chain branches per thousand carbon atoms (SCB_(PE-3)), or from 0 to 20 short chain branches per thousand carbon atoms (SCB_(PE-3)), or from 0 to 15 short chain branches per thousand carbon atoms (SCB_(PE-3)), or from 0 to 10 short chain branches per thousand carbon atoms (SCB_(PE-3)), or from 0 to 5 short chain branches per thousand carbon atoms (SCB_(PE-3)), or fewer than 5 short chain branches per thousand carbon atoms (SCB_(PE-3)), or fewer than 3 short chain branches per thousand carbon atoms (SCB_(PE-3)), or fewer than 1 short chain branches per thousand carbon atoms (SCB_(PE-3)), or about zero short chain branches per thousand carbon atoms (SCB_(PE-23)).

The short chain branching (i.e. the short chain branching per thousand carbons, SCB_(PE-3)) is the branching due to the presence of an alpha-olefin comonomer in the polyethylene and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc.

In embodiments of the disclosure, the upper limit on the density, d3 of the third polyethylene may be about 0.985 g/cm³; in some cases, about 0.975 g/cm³ and, in other cases about 0.965 g/cm³. In embodiments of the disclosure, the lower limit on the density, d3 of the third polyethylene may be about 0.921 g/cm³, in some cases about 0.932 g/cm³, and, in other cases about 0.949 g/cm³.

In embodiments of the disclosure the density, d3 of the third polyethylene may be from about 0.921 g/cm³ to about 0.980 g/cm³, or from about 0.921 g/cm³ to about 0.975 g/cm³, or from about 0.926 g/cm³ to about 0.975 g/cm³, or from about 0.930 g/cm³ to about 0.975 g/cm³, or from about 0.936 g/cm³ to about 0.975 g/cm³, or from about 0.940 g/cm³ to about 0.975 g/cm³, or from about 0.940 g/cm³ to about 0.980 g/cm³, or from about 0.945 g/cm³ to about 0.975 g/cm³, or from about 0.950 g/cm³ to about 0.975 g/cm³, or from about 0.951 g/cm³ to about 0.975 g/cm³, or from about 0.953 g/cm³ to about 0.975 g/cm³, or from about 0.953 g/cm³ to about 0.985 g/cm³.

In embodiments of the disclosure the melt index of the third polyethylene I₂ ³ may be from about 0.1 dg/min to about 10000 dg/min, or from about 0.1 dg/min to about 5000 dg/min, or from about 1 dg/min to about 10000 dg/min, or from about 1 dg/min to about 5000 dg/min, or from about 1 dg/min to about 2500 dg/min, or from about 1 dg/min to about 2000 dg/min, or from about 10 dg/min to about 10000 dg/min, or from about 10 dg/min to about 5000 dg/min, or from about 10 dg/min to about 2500 dg/min, or from about 10 dg/min to about 1000 dg/min, or from about 25 dg/min to about 10000 dg/min, or from about 25 dg/min to about 5000 dg/min, or from about 25 dg/min to about 2500 dg/min, or from about 25 dg/min to about 1000 dg/min.

In an embodiment of the disclosure, the third polyethylene has a weight average molecular weight, M_(w) of from about 10,000 to about 150,000, or from about 10,000 to about 125,000, or from about 15,000 to about 100,000, or from about 15,000 to about 90,000, or from about 15,000 to about 80,000 or from about 20,000 to about 75,000, or from about 20,000 to about 90,000, or from about 20,000 to about 80,000, or from about 15,000 to about 75,000, or from about 10,000 to about 50,000, or from about 15,000 to about 40,000, or from about 12,000 to about 45,000, or from about 12,000 to about 40,000, or less than about 100,000, or less than about 75,000, or less than about 50,000, or less than about 45,000 or less than about 40,000, or less than about 35,000, or less than about 30,000.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene is less than the weight average molecular weight of the first polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene is less than the weight average molecular weight of the fourth polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene is less than the weight average molecular weight of the first polyethylene and the fourth polyethylene.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 25,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 20,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 15,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 10,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 7,500 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 5,000 units (in g/mol) of each other.

In an embodiment of the disclosure, the weight average molecular weight of the third polyethylene and the second polyethylene are within 2,500 units (in g/mol) of each other.

In embodiments of the disclosure, the upper limit on the weight percent (wt. %) of the third polyethylene in the polyethylene composition (i.e. the weight percent of the third polyethylene based on the total weight of the first, the second, the third and the fourth polyethylene) may be about 75 wt. %, or about 70 wt. %, or about 65 wt. %, or about 60 wt. %, or about 55 wt. %, or about 50 wt. %, or about 45 wt. %, or about 40 wt. % or about 35 wt. %. In embodiments of the disclosure, the lower limit on the wt. % of the third polyethylene in the polyethylene composition may be about 1 wt. %, or about 5 wt. %, or about 10 wt. %, or about 15 wt. %, or about 20 wt. %.

The Fourth Polyethylene

In an embodiment of the disclosure, the fourth polyethylene is made with a multi-site catalyst system, non-limiting examples of which include Ziegler-Natta catalysts and chromium catalysts, both of which are well known in the art.

In an embodiment of the disclosure, the fourth polyethylene is made with a Ziegler-Natta catalyst.

Ziegler-Natta catalyst systems are well known to those skilled in the art. A Ziegler-Natta catalyst may be an in-line Ziegler-Natta catalyst system or a batch Ziegler-Natta catalyst system. The term “in-line Ziegler-Natta catalyst system” refers to the continuous synthesis of a small quantity of an active Ziegler-Natta catalyst system and immediately injecting this catalyst into at least one continuously operating reactor, wherein the catalyst polymerizes ethylene and one or more optional α-olefins to form an ethylene polymer. The terms “batch Ziegler-Natta catalyst system” or “batch Ziegler-Natta procatalyst” refer to the synthesis of a much larger quantity of catalyst or procatalyst in one or more mixing vessels that are external to, or isolated from, the continuously operating solution polymerization process. Once prepared, the batch Ziegler-Natta catalyst system, or batch Ziegler-Natta procatalyst, is transferred to a catalyst storage tank. The term “procatalyst” refers to an inactive catalyst system (inactive with respect to ethylene polymerization); the procatalyst is converted into an active catalyst by adding an alkyl aluminum co-catalyst. As needed, the procatalyst is pumped from the storage tank to at least one continuously operating reactor, wherein an active catalyst polymerizes ethylene and one or more optional α-olefins to form a polyethylene. The procatalyst may be converted into an active catalyst in the reactor or external to the reactor, or on route to the reactor.

A wide variety of compounds can be used to synthesize an active Ziegler-Natta catalyst system. The following describes various compounds that may be combined to produce an active Ziegler-Natta catalyst system. Those skilled in the art will understand that the embodiments in this disclosure are not limited to the specific compounds disclosed.

An active Ziegler-Natta catalyst system may be formed from: a magnesium compound, a chloride compound, a metal compound, an alkyl aluminum co-catalyst and an aluminum alkyl. As will be appreciated by those skilled in the art, Ziegler-Natta catalyst systems may contain additional components; a non-limiting example of an additional component is an electron donor, e.g. amines or ethers.

A non-limiting example of an active in-line (or batch) Ziegler-Natta catalyst system can be prepared as follows. In the first step, a solution of a magnesium compound is reacted with a solution of a chloride compound to form a magnesium chloride support suspended in solution. Non-limiting examples of magnesium compounds include Mg(R¹)₂; wherein the R¹ groups may be the same or different, linear, branched or cyclic hydrocarbyl radicals containing 1 to 10 carbon atoms. Non-limiting examples of chloride compounds include R²Cl; wherein R² represents a hydrogen atom, or a linear, branched or cyclic hydrocarbyl radical containing 1 to 10 carbon atoms. In the first step, the solution of magnesium compound may also contain an aluminum alkyl. Non-limiting examples of aluminum alkyl include Al(R³)₃, wherein the R³ groups may be the same or different, linear, branched or cyclic hydrocarbyl radicals containing from 1 to 10 carbon atoms. In the second step a solution of the metal compound is added to the solution of magnesium chloride and the metal compound is supported on the magnesium chloride. Non-limiting examples of suitable metal compounds include M(X)_(n) or MO(X)_(n); where M represents a metal selected from Group 4 through Group 8 of the Periodic Table, or mixtures of metals selected from Group 4 through Group 8; O represents oxygen, and; X represents chloride or bromide; n is an integer from 3 to 6 that satisfies the oxidation state of the metal. Additional non-limiting examples of suitable metal compounds include Group 4 to Group 8 metal alkyls, metal alkoxides (which may be prepared by reacting a metal alkyl with an alcohol) and mixed-ligand metal compounds that contain a mixture of halide, alkyl and alkoxide ligands. In the fourth step a solution of an alkyl aluminum co-catalyst is added to the metal compound supported on the magnesium chloride. A wide variety of alkyl aluminum co-catalysts are suitable, as expressed by formula:

Al(R⁴)_(p)(OR⁹)_(q)(X)_(r)

wherein the R⁴ groups may be the same or different, hydrocarbyl groups having from 1 to 10 carbon atoms; the OR⁹ groups may be the same or different, alkoxy or aryloxy groups wherein R⁹ is a hydrocarbyl group having from 1 to 10 carbon atoms bonded to oxygen; X is chloride or bromide, and; (p+q+r)=3, with the proviso that p is greater than 0. Non-limiting examples of commonly used alkyl aluminum co-catalysts include trimethyl aluminum, triethyl aluminum, tributyl aluminum, dimethyl aluminum methoxide, diethyl aluminum ethoxide, dibutyl aluminum butoxide, dimethyl aluminum chloride or bromide, diethyl aluminum chloride or bromide, dibutyl aluminum chloride or bromide and ethyl aluminum dichloride or dibromide.

The process described in the paragraph above, to synthesize an active in-line (or batch) Ziegler-Natta catalyst system, can be carried out in a variety of solvents; non-limiting examples of solvents include linear or branched C₅ to C₁₂ alkanes or mixtures thereof.

In an embodiment of the disclosure, the fourth polyethylene is an ethylene copolymer. Suitable alpha-olefins which may be copolymerized with ethylene to give the fourth polyethylene include 1-propene, 1-butene, 1-pentene, 1-hexene and 1-octene.

In an embodiment of the disclosure, the fourth polyethylene is an ethylene homopolymer.

In an embodiment of the disclosure, the fourth polyethylene is a heterogeneously branched ethylene copolymer.

In an embodiment of the disclosure, the fourth polyethylene is an ethylene/1-octene copolymer.

In embodiments of the disclosure, the fourth polyethylene has a molecular weight distribution, M_(w)/M_(n) of ≥2.3, or >2.3, or ≥2.5, or >2.5, or ≥2.7, or >2.7, or ≥2.9, or >2.9, or ≥3.0, or 3.0. In embodiments of the disclosure, the fourth polyethylene has a molecular weight distribution, M_(w)/M_(n) of from 2.3 to 7.0, or from 2.3 to 6.5, or from 2.3 to 6.0, or from 2.3 to 5.5, or from 2.5 to 7.0, or from 2.5 to 6.5, or from 2.5 to 6.0, or from 2.5 to 5.5, or from 2.7 to 7.0, or from 2.7 to 6.5, or from 2.7 to 6.0, or from 2.7 to 5.5, or from 2.9 to 7.0, or from 2.9 to 6.5, or from 2.9 to 6.0, or from 2.9 to 5.5.

In an embodiment of the disclosure, the fourth polyethylene has from 0 to 100 short chain branches per thousand carbon atoms (SCB_(PE-4)). In further embodiments, the fourth polyethylene has from 0 to 100 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 0 to 75 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 3 to 100 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 5 to 75 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 5 to 50 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 3 to 50 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 5 to 35 short chain branches per thousand carbon atoms (SCB_(PE-4)), or from 3 to 35 short chain branches per thousand carbon atoms (SCB_(PE-4)).

The short chain branching (i.e. the short chain branching per thousand carbons, SCB_(PE-4)), if present, is the branching due to the presence of alpha-olefin comonomer in the polyethylene and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc.

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the third polyethylene (SCB_(PE-3)).

In an embodiment of the disclosure, the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in both the second polyethylene (SCB_(PE-2)) and the third polyethylene (SCB_(PE-3)).

In embodiments of the disclosure, the upper limit on the density, d4 of the fourth polyethylene may be about 0.975 g/cm³; in some cases, about 0.965 g/cm³ and, in other cases about 0.955 g/cm³. In embodiments of the disclosure, the lower limit on the density, d4 of the fourth polyethylene may be about 0.855 g/cm³, in some cases about 0.865 g/cm³, and, in other cases about 0.875 g/cm³.

In embodiments of the disclosure the density, d4 of the fourth polyethylene may be from about 0.875 g/cm³ to about 0.965 g/cm³, or from about 0.875 g/cm³ to about 0.960 g/cm³, or from about 0.875 g/cm³ to 0.950 g/cm³, or from about 0.865 g/cm³ to about 0.940 g/cm³, or from about 0.865 g/cm³ to about 0.936 g/cm³, or from about 0.865 g/cm³ to about 0.932 g/cm³, or from about 0.865 g/cm³ to about 0.926 g/cm³, or from about 0.865 g/cm³ to about 0.921 g/cm³, or from about 0.865 g/cm³ to about 0.918 g/cm³, or from about 0.865 g/cm³ to about 0.916 g/cm³, or from about 0.875 g/cm³ to about 0.916 g/cm³, or from about 0.865 g/cm³ to about 0.912 g/cm³, or from about 0.880 g/cm³ to about 0.912 g/cm³, or from about 0.890 g/cm³ to about 0.916 g/cm³, or from about 0.900 g/cm³ to about 0.916 g/cm³, or from about 0.880 g/cm³ to about 0.916 g/cm³, or from about 0.880 g/cm³ to about 0.918 g/cm³, or from about 0.880 g/cm³ to about 0.921 g/cm³, or from about 0.880 g/cm³ to about 0.926 g/cm³, or from about 0.880 g/cm³ to about 0.932 g/cm³, or from about 0.880 g/cm³ to about 0.936 g/cm³.

In an embodiment of the disclosure, the fourth polyethylene is an ethylene copolymer which has a composition distribution breadth index, CDBI₅₀ of 75 wt. % or less, or 70 wt. % or less. In further embodiments of the disclosure, the fourth polyethylene is an ethylene copolymer which has a CDBI₅₀ of 65 wt. % or less, or 60 wt. % or less, or 55 wt. % or less, or 50 wt. % or less, or 45 wt. % or less.

In embodiments of the disclosure the melt index of the fourth polyethylene I₂ ⁴ may be from about 0.01 dg/min to about 1000 dg/min, or from about 0.01 dg/min to about 500 dg/min, or from about 0.01 dg/min to about 100 dg/min, or from about 0.01 dg/min to about 50 dg/min, or from about 0.01 dg/min to about 25 dg/min, or from about 0.01 dg/min to about 10 dg/min, or from about 0.01 dg/min to about 5 dg/min, or from about 0.01 dg/min to about 3 dg/min, or from about 0.01 dg/min to about 1 dg/min, or less than about 5 dg/min, or less than about 3 dg/min, or less than about 1.0 dg/min, or less than about 0.75 dg/min, or less than about 0.50 dg/min.

In an embodiment of the disclosure, the fourth polyethylene has a weight average molecular weight, M_(w) of from about 50,000 to about 300,000, or from about 50,000 to about 250,000, or from about 60,000 to about 250,000, or from about 70,000 to about 250,000, or from about 75,000 to about 200,000, or from about 80,000 to about 275,000, or from about 80,000 to about 250,000, or from about 80,000 to about 200,000, or from about 100,000 to about 250,000, or from 70,000 to about 200,000, or from about 80,000 to about 175,000, or from about 75,000 to about 195,000, or from about 75,000 to about 190,000, or from about 100,000 to about 190,000, or from about 100,000 to about 200,000.

In an embodiment of the disclosure, the fourth polyethylene has a weight average molecular weight, M_(w) which is greater than the weight average molecular weight, M_(w) of the second polyethylene.

In an embodiment of the disclosure, the fourth polyethylene has a weight average molecular weight, M_(w) which is greater than the weight average molecular weight, M_(w) of the third polyethylene.

In an embodiment of the disclosure, the fourth polyethylene has a weight average molecular weight, M_(w) which is greater than both the weight average molecular weight, M_(w) of the second polyethylene and the third polyethylene.

In embodiments of the disclosure, the upper limit on the weight percent (wt. %) of the fourth polyethylene in the polyethylene composition (i.e. the weight percent of the fourth polyethylene based on the total weight of the first, the second, the third, and the fourth polyethylene) may be about 90 wt. %, or about 85 wt. %, or about 80 wt. %, or about 75 wt. %, or 65 wt. %, in other cases about 60 wt. %, in other cases about 55 wt. %, or about 50 wt. %, or about 45 wt. %. In embodiments of the disclosure, the lower limit on the wt. % of the fourth polyethylene in the final polyethylene product may be about 5 wt. %, or about 10 wt. %, or about 15 wt. %, or about 20 wt. %, or about 25 wt. %, or about 30 wt. %, or about 35 wt. %, or in other cases about 40 wt. %.

In embodiments of the disclosure, the fourth polyethylene has no long chain branching present or does not have any detectable levels of long chain branching.

The Polyethylene Composition

The polyethylene compositions disclosed herein can be made using any well-known techniques in the art, including but not limited to melt blending, solution blending, or in-reactor blending to bring together a first polyethylene, a second polyethylene, a third polyethylene and a fourth polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made by melt blending or solution blending four different polyethylene components: i) a first polyethylene, ii) a second polyethylene, iii) a third polyethylene, and iv) a fourth polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made by melt blending or solution blending two different polyethylene components: i) a first polyethylene component including a first polyethylene and a second polyethylene, and ii) second polyethylene component including a third polyethylene and a fourth polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made by melt blending or solution blending two different polyethylene components: i) a first polyethylene component including a first polyethylene and a third polyethylene, and ii) a second polyethylene component including a second polyethylene and a fourth polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made by melt blending or solution blending two different polyethylene components: i) a first polyethylene component including a first polyethylene and a fourth polyethylene, and ii) a second polyethylene component including a second polyethylene and a third polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made using the same single site catalyst in two different reactors, where each reactor is operated under different polymerization conditions to give a first polyethylene and a second polyethylene, as well as using a mixed catalyst system including a single site catalyst and a multi-site catalyst in two different reactors, where each reactor is operated under different or the same polymerization conditions to give a third polyethylene and a fourth polyethylene.

In an embodiment, the polyethylene composition of the present disclosure is made using a different single site catalyst in two different reactors, where each reactor is operated under similar or different polymerization conditions to give a first polyethylene and a second polyethylene, as well as using a mixed catalyst system including a single site catalyst and a multi-site catalyst in two different reactors, where each reactor is operated under different or the same polymerization conditions to give a third polyethylene and a fourth polyethylene.

It is also contemplated by the present disclosure, that the polymer compositions including a first, a second, a third and a fourth polyethylene could be made in one or more polymerization reactor, using three different single site polymerization catalysts and a multi-site polymerization catalyst, where each catalyst has a different response to one or more of hydrogen concentration, ethylene concentration, comonomer concentration, and temperature under a given set of polymerization conditions, so that the first polyethylene is produced by the first single site catalyst, the second polyethylene is produced by the second single site catalyst, the third polyethylene is produced by the third single site catalyst and the fourth polyethylene is produced by the multi-site catalyst.

It is also contemplated by the present disclosure, that the polymer compositions including a first, a second, a third and a fourth polyethylene could be made in one or more polymerization reactors, using one or more single site polymerization catalysts, and one multi-site catalyst, where each catalyst has a similar or different response to one or more of hydrogen concentration, ethylene concentration, comonomer concentration, and temperature under a given set of polymerization conditions, and where one or more of hydrogen concentration, ethylene concentration, comonomer concentration, and temperature are cycled through a range so that a first, a second, a third and a fourth polyethylene is produced by the one or more single site catalysts and the one multi-site catalysts present in the one or more polymerization reactors.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second reactor by polymerizing ethylene and optionally an alpha olefin with single site catalyst, forming a third polyethylene in a third reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where at least two of the first, second, third and fourth reactors are configured in series with one another.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first solution phase polymerization reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first solution phase polymerization reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where at least two of the first, second, third and fourth solution phase polymerization reactors are configured in series with one another.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first solution phase polymerization reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where the first and second solution phase polymerization reactors are configured in series with one another and the third and fourth solution phase polymerization reactors are configured in series with one another.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst and forming a fourth polyethylene in a fourth reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where each of the first, second, third and fourth reactors are configured in parallel to one another.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first solution phase polymerization reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth solution phase polymerization reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where each of the first, second, third and fourth solution phase polymerization reactors are configured in parallel to one another.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where the first and second reactors are configured in series to one another, while the third and fourth reactors are configured in series to one another and parallel to the first and second reactors.

In an embodiment, the polyethylene composition of the present disclosure is made by forming a first polyethylene in a first solution phase reactor by polymerizing ethylene and an alpha olefin with a single site catalyst; forming a second polyethylene in a second solution phase reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, forming a third polyethylene in a third solution phase reactor by polymerizing ethylene and optionally an alpha olefin with a single site catalyst, and forming a fourth polyethylene in a fourth solution phase reactor by polymerizing ethylene and optionally an alpha olefin with a multi-site catalyst, where the first and second solution phase reactors are configured in series to one another, while the third and fourth solution phase reactors are configured in series to one another and parallel to the first and second solution phase reactors.

In an embodiment, the solution phase polymerization reactor used as a first solution phase reactor, a second solution phase reactor, a third solution phase reactor, or a fourth solution phase reactor is a continuously stirred tank reactor.

In an embodiment, the solution phase polymerization reactor used as a first solution phase reactor, a second solution phase reactor, a third solution phase reactor, or a fourth solution phase reactor is a tubular reactor.

In a solution phase polymerization reactor, a variety of solvents may be used as the process solvent; non-limiting examples include linear, branched or cyclic C₅ to C₁₂ alkanes. Non-limiting examples of α-olefins include 1-propene, 1-butene, 1-pentene, 1-hexene and 1-octene. Suitable catalyst component solvents include aliphatic and aromatic hydrocarbons. Non-limiting examples of aliphatic catalyst component solvents include linear, branched or cyclic C₅₋₁₂ aliphatic hydrocarbons, e.g. pentane, methyl pentane, hexane, heptane, octane, cyclohexane, cyclopentane, methylcyclohexane, hydrogenated naphtha or combinations thereof. Non-limiting examples of aromatic catalyst component solvents include benzene, toluene (methylbenzene), ethylbenzene, o-xylene (1,2-dimethylbenzene), m-xylene (1,3-dimethylbenzene), p-xylene (1,4-dimethylbenzene), mixtures of xylene isomers, hemellitene (1,2,3-trimethylbenzene), pseudocumene (1,2,4-trimethylbenzene), mesitylene (1,3,5-trimethylbenzene), mixtures of trimethylbenzene isomers, prehenitene (1,2,3,4-tetramethylbenzene), durene (1,2,3,5-tetramethylbenzene), mixtures of tetramethylbenzene isomers, pentamethylbenzene, hexamethylbenzene and combinations thereof.

In embodiments of the disclosure, the polyethylene composition has a density which may be from about 0.880 g/cm³ to about 0.965 g/cm³, or from about 0.885 g/cm³ to about 0.960 g/cm³, or from about 0.890 g/cm³ to 0.950 g/cm³, or from about 0.895 g/cm³ to about 0.940 g/cm³, or from about 0.900 g/cm³ to about 0.936 g/cm³, or from about 0.905 g/cm³ to about 0.934 g/cm³, or from about 0.910 g/cm³ to about 0.932 g/cm³, or from about 0.910 g/cm³ to about 0.930 g/cm³, or from about 0.910 g/cm³ to about 0.926 g/cm³, or from about 0.890 g/cm³ to about 0.924 g/cm³, or from about 0.890 g/cm³ to about 0.922 g/cm³, or from about 0.890 g/cm³ to about 0.920 g/cm³, or from about 0.890 g/cm³ to about 0.918 g/cm³, or from about 0.880 g/cm³ to about 0.922 g/cm³, or from about 0.880 g/cm³ to about 0.926 g/cm³, or from about 0.880 g/cm³ to about 0.932 g/cm³, or ≤0.948 g/cm³, or <0.948 g/cm³, or ≤0.945 g/cm³, or <0.945 g/cm³, or ≤0.940 g/cm³, or <0.940 g/cm³, or ≤0.939 g/cm³, or <0.939 g/cm³, or ≤0.935 g/cm³, or <0.935 g/cm³, or ≤0.932 g/cm³, or <0.932 g/cm³.

In embodiments of the disclosure the melt index I₂ of the polyethylene composition may be from about 0.01 dg/min to about 1000 dg/min, or from about 0.01 dg/min to about 500 dg/min, or from about 0.01 dg/min to about 100 dg/min, or from about 0.01 dg/min to about 50 dg/min, or from about 0.01 dg/min to about 25 dg/min, or from about 0.01 dg/min to about 10 dg/min, or from about 0.01 dg/min to about 5 dg/min, or from about 0.01 dg/min to about 3 dg/min, or from about 0.01 dg/min to about 1 dg/min, or from about 0.1 dg/min to about 10 dg/min, or from about 0.1 dg/min to about 5 dg/min, or from about 0.1 dg/min to about 3 dg/min, or from about 0.1 dg/min to about 2 dg/min, or from about 0.1 dg/min to about 1.5 dg/min, or from about 0.1 dg/min to about 1 dg/min, or less than about 5 dg/min, or less than about 3 dg/min, or less than about 1.0 dg/min.

In embodiments of the disclosure the high load melt index I₂₁ of the polyethylene composition may be from about 15 dg/min to about 10,000 dg/min, or from about 15 dg/min to about 1000 dg/min, or from about 15 dg/min to about 100 dg/min, or from about 15 dg/min to about 75 dg/min, or from about 15 dg/min to about 50 dg/min, or from about 20 dg/min to about 100 dg/min, or from about 20 dg/min to about 75 dg/min, or from about 20 dg/min to about 60 dg/min, or from about 20 dg/min to about 50 dg/mi, or from about 30 dg/min to about 70 dg/min.

In embodiments of the disclosure, the melt flow ratio I₂₁/I₂ of the polyethylene composition is ≤55 or <55, or ≤50, or <50. In embodiments of the disclosure, the melt flow ratio I₂₁/I₂ of the polyethylene composition is >40 or ≥40, or >45, or ≥45. In embodiments of the disclosure the melt flow ratio I₂₁/I₂ of the polyethylene composition is from greater than 40 to 100, or from greater than 40 to 80, or from greater than 40 to 60, or from greater than 40 to 55, or from greater than 40 to less than 55, or from greater than 40 to 50, or from greater than 45 to 100, or from greater than 45 to 80, or from greater than 45 to 60, or from greater than 45 to 55, or from greater than 45 to less than 55, or from 45 to 80, or from 45 to 60, or from 45 to 55, or from 40 to 60, or from 40 to 55, or from 40 to 50.

In embodiments of the disclosure, the polyethylene composition has a weight average molecular weight, M_(w) of from about 50,000 to about 300,000, or from about 50,000 to about 250,000, or from about 60,000 to about 250,000, or from about 70,000 to about 225,000, or from about 70,000 to about 200,000, or from about 75,000 to about 175,000, or from about 75,000 to about 150,000, or from about 100,000 to about 130,000.

In embodiments of the disclosure, the polyethylene composition has a lower limit molecular weight distribution, M_(w)/M_(n) of 2.3, or 2.5, or 2.7, or 2.9. In embodiments of the disclosure, the polyethylene composition has an upper limit molecular weight distribution, M_(w)/M_(n) of 8.0, or 7.5, or 7.0, or 6.5, or 6.0, or 5.5. In embodiments of the disclosure, the polyethylene composition has a molecular weight distribution, M_(w)/M_(n) of from 2.3 to 8.0, or from 2.3 to 7.0, or from 2.3 to 6.5, or from 2.3 to 6.0, or from 2.5 to 6.5, or from 2.5 to 6.0, or from 2.5 to 5.5, or from 2.7 to 6.5, or from 2.7 to 6.0, or from 2.7 to 5.5.

In embodiments of the disclosure, the polyethylene composition has a Z-average molecular weight distribution, M_(Z)/M_(W) of ≤5.0, or <5.0, or ≤4.5, or <4.5, or ≤4.0, or <4.0, or ≤3.5, or <3.5. In embodiments of the disclosure, the polyethylene composition has a Z-average molecular weight distribution, M_(Z)/M_(W) of from 1.5 to 5.5, or from 2.0 to 5.5, or from 2 to 5.0, or from 2.0 to 4.5, or from 2.0 to 4.0, or from 2.25 to 5.0, or from 2.25 to 4.5, or from 2.25 to 4.0.

In an embodiment of the disclosure, the polyethylene composition has a bimodal profile in a gel permeation chromatograph generated according to the method of ASTM D6474-99. The term “unimodal” is herein defined to mean there will be only one significant peak or maximum evident in the GPC-curve. A unimodal profile includes a broad unimodal profile. In contrast, the use of the term “bimodal” is meant to convey that in addition to a first peak, there will be a secondary peak or shoulder which represents a higher or lower molecular weight component (i.e. the molecular weight distribution, can be said to have two maxima in a molecular weight distribution curve). Alternatively, the term “bimodal” connotes the presence of two maxima in a molecular weight distribution curve generated according to the method of ASTM D6474-99. The term “multi-modal” denotes the presence of two or more, typically more than two, maxima in a molecular weight distribution curve generated according to the method of ASTM D6474-99.

In an embodiment of the disclosure the polyethylene composition may have a multimodal profile in a differential scanning calorimetry (DSC) graph. In the context of DSC analysis, the term “multimodal” connotes a DSC profile in which two or more distinct melting peaks are observable.

In an embodiment of the disclosure the polyethylene composition may have a bimodal profile in a differential scanning calorimetry (DSC) graph. In the context of DSC analysis, the term “bimodal” connotes a DSC profile in which two distinct melting peaks are observable.

In an embodiment of the disclosure, the polyethylene composition has a melting peak temperature in a differential scanning calorimetry (DSC) analysis at above 120° C. For clarity sake, by the phrase “has a melting peak temperature in an DSC analysis” it is meant that in a DSC analysis, although there may be one or more melting peaks evident, at least one such peak occurs at above the indicated temperature. In an embodiment of the disclosure, the polyethylene composition has a melting peak temperature in a differential scanning calorimetry (DSC) analysis at above 123° C. In an embodiment of the disclosure, the polyethylene composition has a melting peak temperature in a differential scanning calorimetry (DSC) analysis at above 125° C.

In an embodiment of the disclosure, the polyethylene composition will have a reverse or partially reverse comonomer distribution profile as measured using GPC-FTIR. If the comonomer incorporation decreases with molecular weight, as measured using GPC-FTIR, the distribution is described as “normal”. If the comonomer incorporation is approximately constant with molecular weight, as measured using GPC-FTIR, the comonomer distribution is described as “flat” or “uniform”. The terms “reverse comonomer distribution” and “partially reverse comonomer distribution” mean that in the GPC-FTIR data obtained for a copolymer, there is one or more higher molecular weight components having a higher comonomer incorporation than in one or more lower molecular weight components. The term “reverse(d) comonomer distribution” is used herein to mean, that across the molecular weight range of an ethylene copolymer, comonomer contents for the various polymer fractions are not substantially uniform and the higher molecular weight fractions thereof have proportionally higher comonomer contents (i.e. if the comonomer incorporation rises with molecular weight, the distribution is described as “reverse” or “reversed”). Where the comonomer incorporation rises with increasing molecular weight and then declines, the comonomer distribution is still considered “reverse”, but may also be described as “partially reverse”. A partially reverse comonomer distribution will exhibit a peak or maximum.

In an embodiment of the disclosure the polyethylene composition has a reversed comonomer distribution profile as measured using GPC-FTIR.

In an embodiment of the disclosure the polyethylene composition has a partially reversed comonomer distribution profile as measured using GPC-FTIR.

In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of at least 7.5 wt. % in a crystallization elution fractionation (CEF) analysis, where the soluble fraction is defined as the weight percent (wt. %) of material which elutes at 30° C. and below. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of at least 10 wt. % in a crystallization elution fractionation (CEF) analysis, where the soluble fraction is defined as the weight percent (wt. %) of material which elutes at 30° C. and below. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of at least 12.5 wt. % in a crystallization elution fractionation (CEF) analysis, where the soluble fraction is defined as the weight percent (wt. %) of material which elutes at 30° C. and below. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of from 7.5 wt. % to 30 wt. % in a crystallization elution fractionation (CEF) analysis where the soluble fraction is defined as the weight percent (wt. %) of material which elutes at 30° C. and below. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of from 7.5 wt. % to 25 wt. % in a crystallization elution fractionation analysis. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of from 7.5 wt. % to 20 wt. % in a crystallization elution fractionation (CEF) analysis. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of from 10 wt. % to 25 wt. % in a crystallization elution fractionation (CEF) analysis. In an embodiment of the disclosure, the polyethylene composition has a soluble fraction of from 10 wt. % to 20 wt. % in a crystallization elution fractionation (CEF) analysis.

Without wishing to be bound by theory, the homogeneity of the polyethylene composition may be indicated by a difference in the first and second melting points measured by differential scanning calorimetry (DSC). The melting points in a DSC curve may be indicated by T_(m) ¹ for a first, or lowest melting point, by T_(m) ² for a second melting point, which may occur at the same or higher temperature than the first melting point, by T_(m) ³ for a third melting point, which may occur at the same or higher temperature than the second melting point, and so on.

In embodiments of the disclosure, the polyethylene composition has a T_(m) ²−T_(m) ¹ of less than 45° C., or less than 40° C., or 40° C.

In embodiments of the disclosure, the polyethylene composition has a T_(m) ²−T_(m) ¹ of from 15 to 45° C., or from 20 to 45° C., or from 25 to 45° C., or from 20 to 40° C., or from 25 to 40° C., or from 30 to 45° C., or from 30 to 40° C. (note: by a T_(m) ²−T_(m) ¹=0, it is meant that there is no separate or distinct Tm² peak measured by DSC, with only a Tm¹ being observed; effectively the T_(m) ² and the T_(m) ¹ are equal).

In an embodiment of the disclosure, the polyethylene composition has a stress exponent, defined as Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16], which is ≤1.8. In further embodiments of the disclosure the polyethylene composition has a stress exponent, Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16] of less than 1.76, or less than 1.70.

In an embodiment of the disclosure, the polyethylene composition has a hexane extractable value of ≤5.0 weight percent, or less than 4.0 wt. %, or less than 3.0 wt. %, or less than 2.0 wt. %, or less than 1.5 wt. %, or less than 1.0 wt. %.

The polyethylene composition disclosed herein may be converted into flexible manufactured articles such as monolayer or multilayer films, such films are well known to those experienced in the art; non-limiting examples of processes to prepare such films include blown film and cast film processes.

In the blown film extrusion process an extruder heats, melts, mixes and conveys a thermoplastic, or a thermoplastic blend. Once molten, the thermoplastic is forced through an annular die to produce a thermoplastic tube. In the case of co-extrusion, multiple extruders are employed to produce a multilayer thermoplastic tube. The temperature of the extrusion process is primarily determined by the thermoplastic or thermoplastic blend being processed, for example the melting temperature or glass transition temperature of the thermoplastic and the desired viscosity of the melt. In the case of polyolefins, typical extrusion temperatures are from 330° F. to 550° F. (166° C. to 288° C.). Upon exit from the annular die, the thermoplastic tube is inflated with air, cooled, solidified and pulled through a pair of nip rollers. Due to air inflation, the tube increases in diameter forming a bubble of desired size. Due to the pulling action of the nip rollers the bubble is stretched in the machine direction. Thus, the bubble is stretched in two directions: the transverse direction (TD) where the inflating air increases the diameter of the bubble; and the machine direction (MD) where the nip rollers stretch the bubble. As a result, the physical properties of blown films are typically anisotropic, i.e. the physical properties differ in the MD and TD directions; for example, film tear strength and tensile properties typically differ in the MD and TD. In some prior art documents, the terms “cross direction” or “CD” is used; these terms are equivalent to the terms “transverse direction” or “TD” used in this disclosure. In the blown film process, air is also blown on the external bubble circumference to cool the thermoplastic as it exits the annular die. The final width of the film is determined by controlling the inflating air or the internal bubble pressure; in other words, increasing or decreasing bubble diameter. Film thickness is controlled primarily by increasing or decreasing the speed of the nip rollers to control the draw-down rate. After exiting the nip rollers, the bubble or tube is collapsed and may be slit in the machine direction thus creating sheeting. Each sheet may be wound into a roll of film. Each roll may be further slit to create film of the desired width. Each roll of film is further processed into a variety of consumer products as described below.

The cast film process is similar in that a single or multiple extruder(s) may be used; however, the various thermoplastic materials are metered into a flat die and extruded into a monolayer or multilayer sheet, rather than a tube. In the cast film process the extruded sheet is solidified on a chill roll.

Depending on the end-use application, the disclosed polyethylene composition may be converted into films that span a wide range of thicknesses. Non-limiting examples include, food packaging films where thicknesses may range from about 0.5 mil (13 μm) to about 4 mil (102 μm), and; in heavy duty sack applications film thickness may range from about 2 mil (51 μm) to about 10 mil (254 μm).

The polyethylene composition disclosed herein may be used in monolayer films; where the monolayer may contain more than one polyethylene composition and/or additional thermoplastics; non-limiting examples of thermoplastics include polyethylene polymers and propylene polymers. The lower limit on the weight percent of the polyethylene composition in a monolayer film may be about 3 wt. %, in other cases about 10 wt. % and in still other cases about 30 wt. %. The upper limit on the weight percent of the polyethylene composition in the monolayer film may be 100 wt. %, in other cases about 90 wt. % and in still other cases about 70 wt. %.

The polyethylene composition disclosed herein may also be used in one or more layers of a multilayer film; non-limiting examples of multilayer films include three, five, seven, nine, eleven or more layers. The thickness of a specific layer (containing the polyethylene composition) within a multilayer film may be about 5%, in other cases about 15% and in still other cases about 30% of the total multilayer film thickness. In other embodiments, the thickness of a specific layer (containing the polyethylene composition) within a multilayer film may be about 95%, in other cases about 80% and in still other cases about 65% of the total multilayer film thickness. Each individual layer of a multilayer film may contain more than one polyethylene composition and/or additional thermoplastics.

In an embodiment of the disclosure, the polyethylene composition disclosed herein is used in a thermoformable film.

Thermoforming is a process in which a thermoplastic film or sheet is heated to a temperature at which the film or sheet is pliable and then stretched over and into the opening of a single-sided mold. The film is held in place over the contours of the mold while it cools and solidifies into the corresponding mold shape. During thermoforming, the film may be clamped in place on the mold and heated using convective or radiant heat to soften the film. The film or sheet, which is held horizontally over a mold cavity is then pressed, stretched or pulled into the mold using air pressure (applied to the back side of the film to push it into the mold cavity) or mechanical force (in which a die physically forces the film into the mold cavity by direct contact) optionally together with vacuum pressure (applied between the mold cavity and the film to pull the film into the mold cavity). The softened film then takes up the shape of the mold and is held in place until it cools and solidifies. Excess material is trimmed away from the edges of the mold, and the part released from the mold.

Thermoforming is also a known packaging process in which a container (e.g. a tray) is formed from a plastic film in a mold by application of vacuum, air pressure or a plug under increased temperature. Foodstuff is placed in the container and air is drawn from the packaging prior to sealing it with another film which is separate from the film used to make the container or tray. In foodstuff packing applications then, a thermoforming process generally involves two packaging films: a top lid film which seals (optionally under vacuum) to a bottom film which is made into a container; and a bottom thermoformable film which is formed into a tray during the first step of the packaging process and wherein the food is placed prior to the sealing step.

It is known to persons skilled in the art that nylon polymers have good performance in multilayer film thermoforming applications. It is also known, that when used in blends with polyethylene, cyclic olefin copolymers (e.g. TOPAS™ COC) enhance performance in film thermoforming applications. As these cyclic olefin copolymers have relatively high cost, it would be desirable to produce other polyethylene copolymers affording good performance in film thermoforming applications. Especially useful would be novel ethylene rich polyethylene copolymers (e.g. ethylene copolymers which contain less than about 30 wt. % of comonomer) which could be used in the absence of nylons in all polyethylene film structures for enhanced recyclability.

Thermoforming can be applied to both rigid and flexible packaging. Somewhere in-between, semi-rigid packaging exists. Typical thermoforming temperatures for multilayer packaging films involving polyethylenes is from 85° C. to 110° C.

Techniques have been used to predict polymer thermoformability, and these methods are available to persons skilled in the art. For a semi-crystalline polymer, it is desirable that such a screening tool reflect the total contributions of both the melt state (as represented by the amorphous phase) and the solid state (as represented by the crystalline phase) of the polymer. Failure to recognize the contributions from both phases cannot reflect the true physical state of a specimen in a real thermoforming process involving semi-crystalline polymers. One such method to reflect the total contributions of both amorphous and crystalline phases in the whole sample for a semi-crystalline polymer is concerned with the dimensional uniformity of a film when the film is subjected to conditions which approximate those encountered in a thermoforming process. This proxy test method determines the so-called “area Dimensional Thermoformability Index” or the “aDTI” and serves as a useful tool to predict the expected performance of a given film in a thermoforming application (see for example, XiaoChuan Wang and Mini Boparai, Annual Technical Conference of the Society of Plastics Engineers, May 16-20, 2010, Orlando, Fla., USA). In the present disclosure, a modified version of this methodology is used to predict the thermoformability of a polyethylene composition or an ethylene-comprising polymer with respect to thickness distribution uniformity or tendency of corner thinning, and this method is described below in the Examples section. Use of the modified method allows a person skilled in the art to assess or rank the dimensional thermoformability of an ethylene copolymer against commercially available resins known to have good or bad thermoformability using typical thermoforming conditions for films including polyethylenes. The lower the area DTI, the better the dimensional thermoformability. A lower aDTI value suggests that the film of a polymer may have a higher thickness distribution uniformity or less tendency toward corner thinning during thermoforming compared to another polymer with a higher aDTI value under the same deformation conditions.

In an embodiment of the disclosure, a thermoformable film is a single layer film (i.e. a monolayer film).

In an embodiment of the disclosure, a thermoformable film is a multilayer film.

In embodiments of the disclosure, a thermoformable film or sheet or thermoformable film layer has a thickness of from 3 to 20 mils.

In embodiments of the disclosure, a thermoformable multilayer film or sheet structure has a thickness of from 3 to 20 mils.

In embodiments of the disclosure, a thermoformable film or sheet or thermoformable film layer includes the polyethylene composition described above.

In an embodiment of the disclosure, a thermoformable multilayer film or sheet structure includes a film layer including the polyethylene composition described above.

In embodiments of the disclosure, a thermoformable film or sheet or thermoformable film layer includes the polyethylene composition described above and has a thickness of from 3 to 20 mils.

In an embodiment of the disclosure, a thermoformable multilayer film or sheet structure includes a film layer including the polyethylene composition described above and the multilayer film or sheet structure has a thickness of from 3 to 20 mils.

In embodiments of the disclosure, the polyethylene composition will have an area Dimensional Thermoformability Index (“aDTI”) determined at 105° C., of less than 20, or less than 15, or less than 10, or less than 7.5, or 20, or 15, or 10, or 7.5.

In embodiments of the disclosure, the polyethylene composition will have an area Dimensional Thermoformability Index (“aDTI”) determined at 105° C., of from 1 to 20, or from 1 to 15, or from 1 to 10, or from 1 to 7.5, or from 2 to 15, or from 2 to 10, or from 2 to 7.5, or from 3 to 7, or from 4 to 7.

The films used in the manufactured articles described in this section may optionally include, depending on its intended use, additives and adjuvants. Non-limiting examples of additives and adjuvants include, anti-blocking agents, antioxidants, heat stabilizers, slip agents, processing aids, anti-static additives, colorants, dyes, filler materials, light stabilizers, light absorbers, lubricants, pigments, plasticizers, nucleating agents and combinations thereof.

The following examples are presented for the purpose of illustrating selected embodiments of this disclosure; it being understood, that the examples presented do not limit the claims presented.

EXAMPLES Test Methods

Prior to testing (those proper tests that are not for high temperature tensile experiments described later), each specimen was conditioned for at least 24 hours at 23±2° C. and 50±10% relative humidity and subsequent testing was conducted at 23±2° C. and 50±10% relative humidity. Herein, the term “ASTM conditions” refers to a laboratory that is maintained at 23±2° C. and 50±10% relative humidity; and specimens to be tested were conditioned for at least 24 hours in this laboratory prior to testing. ASTM refers to the American Society for Testing and Materials.

Density was determined using ASTM D792-13 (Nov. 1, 2013).

Melt index was determined using ASTM D1238 (Aug. 1, 2013). Melt indexes, I₂, I₆, I₁₀ and I₂₁ were measured at 190° C., using weights of 2.16 kg, 6.48 kg, 10 kg and a 21.6 kg respectively. Herein, the term “stress exponent” or its acronym “S.Ex.”, is defined by the following relationship: S.Ex.=log (I₆/I₂)/log(6480/2160); wherein I₆ and I₂ are the melt flow rates measured at 190° C. using 6.48 kg and 2.16 kg loads, respectively.

M_(n), M_(w), and M_(z) (g/mol) were determined by high temperature Gel Permeation Chromatography (GPC) with differential refractive index (DRI) detection using universal calibration (e.g. ASTM-D6474-99). GPC data was obtained using an instrument sold under the trade name “Waters 150c”, with 1,2,4-trichlorobenzene as the mobile phase at 140° C. The samples were prepared by dissolving the polymer in this solvent and were run without filtration. Molecular weights are expressed as polyethylene equivalents with a relative standard deviation of 2.9% for the number average molecular weight (“Mn”) and 5.0% for the weight average molecular weight (“Mw”). The molecular weight distribution (MWD) is the weight average molecular weight divided by the number average molecular weight, M_(W)/M_(n). The z-average molecular weight distribution is M_(z)/M_(n). Polymer sample solutions (1 to 2 mg/mL) were prepared by heating the polymer in 1,2,4-trichlorobenzene (TCB) and rotating on a wheel for 4 hours at 150° C. in an oven. The antioxidant 2,6-di-tert-butyl-4-methylphenol (BHT) was added to the mixture in order to stabilize the polymer against oxidative degradation. The BHT concentration was 250 ppm. Sample solutions were chromatographed at 140° C. on a PL 220 high-temperature chromatography unit equipped with four Shodex columns (HT803, HT804, HT805 and HT806) using TCB as the mobile phase with a flow rate of 1.0 mL/minute, with a differential refractive index (DRI) as the concentration detector. BHT was added to the mobile phase at a concentration of 250 ppm to protect the columns from oxidative degradation. The sample injection volume was 200 mL. The raw data were processed with Cirrus GPC software. The columns were calibrated with narrow distribution polystyrene standards. The polystyrene molecular weights were converted to polyethylene molecular weights using the Mark-Houwink equation, as described in the ASTM standard test method D6474.

The short chain branch frequency (e.g. the short chain branching per thousand backbone carbon atoms, or the SCB/1000C) of ethylene copolymer samples was determined by Fourier Transform Infrared Spectroscopy (FTIR) as per the ASTM D6645-01 method. A Thermo-Nicolet 750 Magna-IR Spectrophotometer equipped with OMNIC version 7.2a software was used for the measurements. Unsaturations in the polyethylene composition were also determined by Fourier Transform Infrared Spectroscopy (FTIR) as per ASTM D3124-98.

High temperature GPC equipped with an online FTIR detector (GPC-FTIR) was used to measure the comonomer content as the function of molecular weight.

Crystallization Elution Fractionation (CEF): A polymer sample (20 to 25 mg) was weighed into the sample vial and loaded onto the auto-sampler of the Polymer CEF unit. The vail was filled with 6 to 7 ml 1,2,4-trichlorobenzene (TCB), heated to the desired dissolution temperature (e.g. 160° C.) with a shaking rate of level number 3 for 2 hours. The solution (0.5 ml) was then loaded into the CEF columns (two CEF columns purchased from Polymer Char and installed in series). After allowed to equilibrate at a given stabilization temperature (e.g. 115° C.) for 5 minutes, the polymer solution was allowed to crystallize with a temperature drop from the stabilization temperature to 30° C. After equilibrating at 30° C. for 10 minutes, the soluble fraction was eluted at 30° C. for 10 minutes, followed by the crystallized sample eluted with TCB with a temperature ramp from 30° C. to 110° C. The CEF columns were cleaned at the end of the run for 5 minutes at 150° C. The other CEF run conditions were as follows: cooling rate 0.5° C./minute, flow rate in crystallization 0.02 mL/minute, heating rate 1.0° C./minute and flow rate in elution 2.0 mL/minute. The data were processed using Excel spreadsheet. The “CDBI₅₀” is defined as the weight percent of ethylene polymer whose composition is within 50% of the median comonomer composition (50% on each side of the median comonomer composition). The “CDBI₅₀” may be calculated from the composition distribution curve, determined by the CEF procedure described above, and the normalized cumulative integral of the composition distribution curve, as illustrated in U.S. Pat. No. 5,376,439 or WO 93/03093.

The “Composition Distribution Branching Index” or “CDBI” may alternatively by determined using a crystal-TREF unit commercially available form Polymer ChAR (Valencia, Spain). The acronym “TREF” refers to Temperature Rising Elution Fractionation. A sample of the polyethylene composition (80 to 100 mg) was placed in the reactor of the Polymer ChAR crystal-TREF unit, the reactor was filled with 35 ml of 1,2,4-trichlorobenzene (TCB), heated to 150° C. and held at this temperature for 2 hours to dissolve the sample. An aliquot of the TCB solution (1.5 mL) was then loaded into the Polymer ChAR TREF column filled with stainless steel beads and the column was equilibrated for 45 minutes at 110° C. The polyethylene composition was then crystallized from the TCB solution, in the TREF column, by slowly cooling the column from 110° C. to 30° C. using a cooling rate of 0.09° C. per minute. The TREF column was then equilibrated at 30° C. for 30 minutes. The crystallized polyethylene composition was then eluted from the TREF column by passing pure TCB solvent through the column at a flow rate of 0.75 m L/minute as the temperature of the column was slowly increased from 30° C. to 120° C. using a heating rate of 0.25° C. per minute. Using Polymer ChAR software a TREF distribution curve was generated as the polyethylene composition was eluted from the TREF column, i.e. a TREF distribution curve is a plot of the quantity (or intensity) of polyethylene composition eluting from the column as a function of TREF elution temperature. A CDBI₅₀ may be calculated from the TREF distribution curve for each polyethylene composition analyzed. The “CDBI₅₀” is defined as the weight percent of ethylene polymer whose composition is within 50% of the median comonomer composition (50% on each side of the median comonomer composition); it is calculated from the TREF composition distribution curve and the normalized cumulative integral of the TREF composition distribution curve. Those skilled in the art will understand that a calibration curve is required to convert a TREF elution temperature to comonomer content, i.e. the amount of comonomer in the polyethylene composition fraction that elutes at a specific temperature. The generation of such calibration curves are described in the prior art, e.g. Wild, et al., J. Polym. Sci., Part B, Polym. Phys., Vol. 20 (3), pages 441-455: hereby fully incorporated by reference. Note: The “CDBI₂₅” is defined as the weight percent of polyethylene composition whose composition is within 25% of the median comonomer composition (25% on each side of the median comonomer composition).

Dynamic mechanical analyses were carried out with a rheometer, namely Rheometrics Dynamic Spectrometer (RDS-II) or Rheometrics SR5 or ATS Stresstech, on compression molded samples under nitrogen atmosphere at 190° C., using 25 mm diameter cone and plate geometry. The oscillatory shear experiments were done within the linear viscoelastic range of strain (10% strain) at frequencies from 0.05 to 100 rad/s. The values of storage modulus (G′), loss modulus (G″), complex modulus (G*) and complex viscosity (η*) were obtained as a function of frequency. The same rheological data can also be obtained by using a 25 mm diameter parallel plate geometry at 190° C. under nitrogen atmosphere. The Zero shear viscosity is estimated using the Ellis model, i.e. η(ω)=η₀/(1+τ/τ_(1/2))^(α-1), where η₀ is the zero shear viscosity. τ_(1/2) is the value of the shear stress at which η=η₀/2 and α is one of the adjustable parameters. The Cox-Merz rule is assumed to be applicable in the present disclosure.

The DRI, is the “Dow rheology index”, and is defined by the equation: DRI=[365000(τ₀/η₀)−1]/10; wherein τ₀ is the characteristic relaxation time of the polyethylene and η₀ is the zero shear viscosity of the material. The DRI is calculated by least squares fit of the rheological curve (dynamic complex viscosity versus applied frequency e.g. 0.01-100 rads/s) as described in U.S. Pat. No. 6,114,486 with the following generalized Cross equation, i.e. η(ω)=η₀/[1+(∫τ₀)^(n)]; wherein n is the power law index of the material, η(ω) and ω are the measured complex viscosity and applied frequency data respectively. When determining the DRI, the zero shear viscosity, η₀ used was estimated with the Ellis model, rather than the Cross model.

The crossover frequency is the frequency at which storage modulus (G′) and loss modulus (G″) curves cross with each other, while G′@G″=500 Pa is the storage modulus at which the loss modulus (G″) is at 500 Pa.

Primary melting peak (° C.), melting peak temperatures (° C.), heat of fusion (J/g) and crystallinity (%) was determined using differential scanning calorimetry (DSC) on a TA Instrument DSC Q2000 Thermal Analyzer as follows: the instrument was first calibrated with indium; after the calibration, a polymer specimen is equilibrated at 0° C. and then the temperature was increased to 200° C. at a heating rate of 10° C./min; the melt was then kept isothermally at 200° C. for five minutes; the melt was then cooled to 0° C. at a cooling rate of 10° C./min and kept at 0° C. for five minutes; the specimen was then heated to 200° C. at a heating rate of 10° C./min. The DSC Tm, heat of fusion and crystallinity are reported from the 2^(nd) heating cycle.

The hexane extractable content of a polymer sample was determined according to the Code of Federal Registration 21 CFR § 177.1520 Para (c) 3.1 and 3.2; wherein the quantity of hexane extractable material in a film is determined gravimetrically. Elaborating, 2.5 grams of 3.5 mil (89 μm) monolayer film was placed in a stainless steel basket, the film and basket were weighed (w^(i)), while in the basket the film was: extracted with n-hexane at 49.5° C. for two hours; dried at 80° C. in a vacuum oven for 2 hours; cooled in a desiccator for 30 minutes, and; weighed (we). The percent loss in weight is the percent hexane extractable (w^(C6)): w^(C6)=100×(w^(i)−w^(f))/w^(i).

The average Melt Strain Hardening Index (the “MSHI”): The transient extensional rheology of resins was studied using a host rotational rheometer sold under the name Sentmanat™ Extensional Rheometer (“SER”). Rectangular samples with pre-measured dimensions were mounted between the fixing clamps and were heated up to the measurement temperature. The resulting torques M was then monitored upon stretching of the mounted sample as a function of time at a constant Hencky strain rate ({dot over (ε)}_(H)) ranging between 0.01-10 s⁻¹. The transient extensional viscosity η_(E)*(t) was calculated using the following equation:

${\eta_{E}^{*}(t)} = \frac{M(t)}{2R\;{\overset{.}{ɛ}}_{H}{A(T)}{\exp\left( {{- {\overset{.}{ɛ}}_{H}}t} \right)}}$

in which R is the SER drum radius (5.155 mm) and A(T) is the corrected cross-sectional area of the sample as a function of temperature. The cross-sectional area of the sample at the testing temperature was estimated using the equation in below:

${A(T)} = {A_{0}\left( \frac{\rho_{s}}{\rho_{m}(T)} \right)}^{2/3}$

in which A₀, ρ_(s) and ρ_(m) are the measured cross-sectional area in solid-state, the sample solid-state density and the melt-state density at temperature T. A parameter, the Melt Strain Hardening Index (MSHI) or η_(E)*/η_(Linear)*, is calculated as follows using the transient extensional viscosity data tested at 150° C. and 0.3⁻¹ Henky strain rate:

-   -   a) The data from 1 to 4 seconds are fitted to obtain a linear         equation of η_(Linear)* vs time (η_(Linear)*=a+b*time). If the         slope (b value) is less than 0, the average MSHI is defined as         “<0.98”.     -   b) The data starting from 4 seconds to the end point (tf) where         the data is still reliable are selected. Then the Melt Strain         Hardening Index (MSHI)=η_(E)*/η_(Linear)* for each experimental         point is calculated, where r_(i)E*is the tested extensional         viscosity and η_(Linear)* is the calculated value using the         above fitted equation, for each experimental point between 4 to         t_(f) seconds.     -   c) The average MSHI (time=4 to t_(f) seconds) is then obtained         by averaging the MSHI data from 4 to t_(f) seconds.         An example of calculating the average melt strain hardening         index (MSHI) is shown in FIG. 5.

Polyethylene Compositions

Polyethylene compositions comprising a first, second, third and fourth polyethylene were made by melt blending polyethylene compositions A, B, or C with polyethylene compositions D, E or F respectively.

The polyethylene compositions A, B and C were each made using two different single site catalysts in a dual parallel reactor solution polymerization process. As a result, polyethylene compositions A, B and C comprised a first polyethylene made with first single site catalyst (a metallocene) and a second polyethylene made with a second single site catalyst (a phosphinimine catalyst). A parallel mode solution phase polymerization reactor process has been described in U.S. Pat. No. 10,442,920. Basically, in parallel mode the exit streams exiting each of a first reactor (R1) and a second reactor (R2) are combined downstream of each reactor and the polymer product is obtained after devolatilization.

The following examples illustrate the continuous solution copolymerization of ethylene and 1-octene at medium pressure in a dual reactor system connected in parallel. The first and second reactor pressure was about 16,000 kPa (about 2.3×10³ psi). The first reactor was operated at a lower temperature than the second reactor. The first reactor had a volume of 12 liters and the second reactor had a volume of 24 liters. Both reactors were agitated to ensure good mixing of the reactor contents. The process was continuous in all feed streams (i.e. solvents, which were methyl pentane and xylene; monomers and catalyst and cocatalyst components) and in the removal of product. Monomer (ethylene) and comonomer (1-octene) were purified prior to addition to the reactor using conventional feed preparation systems (such as contact with various absorption media to remove impurities such as water, oxygen and polar contaminants). The reactor feeds were pumped to the reactors at the ratios shown in Table 1. Average residence times for the reactors are calculated by dividing average flow rates by reactor volume. The residence time in each reactor for all of the experiments was less than 10 minutes and the reactors were well mixed. The catalyst deactivator used was octanoic acid (caprylic acid), commercially available from P&G Chemicals, Cincinnati, Ohio, U.S.A.

The following single site catalyst (SSC) components were used to prepare the first polyethylene in a first reactor (R1) configured in parallel to a second reactor (R2): diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethide [(2,7-tBu₂Flu)Ph₂C(Cp)HfMe₂]; methylaluminoxane (MMAO-07); trityl tetrakis(pentafluoro-phenyl)borate (trityl borate), and 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO-07) and 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethide and trityl tetrakis(pentafluoro-phenyl)borate just before entering the polymerization reactor (R1).

The following single site catalyst (SSC) components were used to prepare the second polyethylene in a second reactor (R2) configured in parallel to a first reactor (R1): cyclopentadienyl tri(tertiary butyl)phosphinimine titanium dichloride [Cp((t-Bu)₃PN)TiCl₂]; methylaluminoxane (MMAO-07); trityl tetrakis(pentafluoro-phenyl)borate (trityl borate), and 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO-07) and 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with cyclopentadienyl tri(tertiarybutyl)phosphinimine titanium dichloride [Cp((t-Bu)₃PN)TiCl₂] and trityl tetrakis(pentafluoro-phenyl)borate just before entering the polymerization reactor (R2).

Polyethylene compositions D, E and F were each made using a mixed dual catalyst system in a dual parallel reactor solution polymerization process. As a result, polyethylene compositions D, E and F, each comprised a third polyethylene made with a single site catalyst (a phosphinimine catalyst) and a fourth polyethylene made with a Ziegler-Natta catalyst. A parallel mode solution phase polymerization reactor process, including one employing a mixed dual catalyst has been described in U.S. Pat. No. 10,442,920. Basically, in parallel mode the exit streams exiting each of a first reactor (R1) and a second reactor (R2) are combined downstream of each reactor and the polymer product is obtained after devolatilization.

The following examples illustrate the continuous solution copolymerization of ethylene and 1-octene at medium pressure in a dual reactor system connected in parallel. The first and second reactor pressure was about 16,000 kPa (about 2.3×10³ psi). The first reactor was operated at a lower temperature than the second reactor. The first reactor had a volume of 12 liters and the second reactor had a volume of 24 liters. Both reactors were agitated to ensure good mixing of the reactor contents. The process was continuous in all feed streams (i.e. solvent, which was methyl pentane; monomers and catalyst and cocatalyst components) and in the removal of product. Monomer (ethylene) and comonomer (1-octene) were purified prior to addition to the reactor using conventional feed preparation systems (such as contact with various absorption media to remove impurities such as water, oxygen and polar contaminants). The reactor feeds were pumped to the reactors at the ratios shown in Table 1. Average residence times for the reactors are calculated by dividing average flow rates by reactor volume. The residence time in each reactor for all of the experiments was less than 10 minutes and the reactors were well mixed.

The following single site catalyst (SSC) components were used to prepare the third polyethylene in a second reactor (R2) configured in parallel to a first reactor (R1): cyclopentadienyl tri(tertiary butyl)phosphinimine titanium dichloride [Cp((t-Bu)₃PN)TiCl₂]; methylaluminoxane (MMAO-07); trityl tetrakis(pentafluoro-phenyl)borate (trityl borate), and 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO-07) and 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with cyclopentadienyl tri(tertiary butyl)phosphinimine titanium dichloride [Cp((t-Bu)₃PN)TiCl₂] and trityl tetrakis(pentafluoro-phenyl)borate just before entering the polymerization reactor (R2).

The following Ziegler-Natta (ZN) catalyst components were used to prepare the fourth polyethylene in a first reactor (R1) configured in parallel to a second reactor (R2): butyl ethyl magnesium; tertiary butyl chloride; titanium tetrachloride; diethyl aluminum ethoxide; and triethyl aluminum. Methylpentane was used as the catalyst component solvent and the in-line Ziegler-Natta catalyst formulation was prepared using the following steps. In step one, a solution of triethylaluminum and butyl ethyl magnesium (Mg:Al=20, mol:mol) was combined with a solution of tertiary butyl chloride and allowed to react for about 30 seconds to produce a MgCl₂ support. In step two, a solution of titanium tetrachloride was added to the mixture formed in step one and allowed to react for about 14 seconds prior to injection into first reactor (R1). The in-line Ziegler-Natta catalyst was activated in the reactor by injecting a solution of diethyl aluminum ethoxide into R1. The quantity of titanium tetrachloride added to the reactor is shown in Table 1. The efficiency of the in-line Ziegler-Natta catalyst formulation was optimized by adjusting the mole ratios of the catalyst components.

Table 1, shows the reactor conditions used to make polyethylene compositions A, B, C, D, E and F. The properties of polyethylene compositions A, B, C, D, E and F are shown in Table 2.

TABLE 1 Reactor Operating Conditions Blending Component PE PE PE PE PE PE Composition A Composition B Composition C Composition D Composition E Composition F Description SSC in R1 ZN in R1 and ZN in R1 and ZN in R1 and SSC in R1 and SSC in R1 and and SSC in SSC in R2 SSC in R2 SSC in R2 SSC in R2 SSC in R2 R2 (dual (dual reactor (dual reactor (dual reactor (dual reactor in (dual reactor in reactor in in parallel in parallel in parallel parallel mode) parallel mode) parallel mode) mode) mode) mode) Reactor 1 (R1) metallocene metallocene metallocene ZN ZN ZN TSR (kg/hr) 370 389.8 367.2 294.9 413.3 273.9 Ethylene 9.5 9.7 9.7 7.1 9.7 9.3 concentration (wt %) 1-Octene/ethylene 0.53 0.54 0.53 2.43 0.96 1.18 in fresh feed (g/g) Primary feed 35.0 35.0 35.1 35.0 35.0 35.0 temperature (° C.) Mean Temperature 144.4 145.9 145.9 125.3 149.4 146.7 (° C.) Ethylene conversion 80 80 80 86.32 87.91 85.02 Hydrogen Feed 0.2 5.0 2.0 0.2 1.3 1.0 (ppm) Catalyst (ppm) to R1 0.79 0.59 0.67 4.40 5.33 3.86 SSC − Al/Hf 31 31 31 N/A N/A N/A (mol/mol) SSC − BHEB/Al 0.4 0.4 0.4 N/A N/A N/A (mol/mol) SSC − B/Hf 1.22 1.22 1.22 N/A N/A N/A (mol/mol) ZN − N/A N/A N/A 2.1 2.1 2.1 tertbutylchloride/Mg (mol/mol) ZN − Mg/Ti N/A N/A N/A 7.0 7.0 7.0 (mol/mol) ZN − diethyl N/A N/A N/A 1.35 1.35 1.35 aluminum ethoxide/Ti (mol/mol) Reactor 2 (R2) phosphinimine phosphinimine phosphinimine phosphinimine phosphinimine phosphinimine TSR (kg/hr) 155.0 135.2 157.8 305.1 136.8 326.1 Ethylene 12.7 13.8 12.7 12.7 13.8 12.7 concentration (wt %) 1-Octene/ethylene 0.0 0.0 0.0 0.0 0.0 0.0 in fresh feed (g/g) Primary feed 44.9 45.8 45.2 45.0 44.5 45.0 temperature (° C.) Mean Temperature 189.9 200.3 190.1 190.9 200.1 191.1 (° C.) Ethylene conversion 90 90 90 90.5 89.6 90.4 Hydrogen Feed 18.5 39.9 13.8 18.5 40.0 13.8 (ppm) Catalyst (ppm) to R2 0.35 0.70 0.32 0.59 0.97 0.48 SSC − Al/Ti 65 65 65 100 100 100 (mol/mol) SSC − BHEB/Al 0.3 0.3 0.3 0.3 0.3 0.3 (mol/mol) SSC − B/Ti (mol/mol) 1.5 1.5 1.5 1.2 1.2 1.2

TABLE 2 Blend Component Properties Blending Component PE PE PE PE PE PE Composition Composition Composition Composition Composition Composition A B C D E F Description SSC in R1 SSC in R1 SSC in R1 and SSC in and SSC in and SSC in ZN in R1 and ZN in R1 and ZN in R1 and R2 (dual R2 (dual R2 (dual SSC in R2 SSC in R2 SSC in R2 reactor in reactor in reactor in (dual reactor (dual reactor (dual reactor parallel parallel parallel in parallel in parallel in parallel mode) mode) mode) mode) mode) mode) Catalysts SSC/SSC SSC/SSC SSC/SSC ZN/SSC ZN/SSC ZN/SSC Density (g/cm³) 0.9096 0.9088 0.9099 0.937 0.9278 0.9418 Melt Index I₂ (g/10 0.32 1.45 0.58 2.04 0.34 3.02 min) Melt Index I₆ (g/10 2.07 7.08 3.30 17.9 2.58 19 min) Melt Index I₁₀ (g/10 4.09 14.3 6.36 42.8 4.73 40.9 min) Melt Index I₂₁ (g/10 20.4 61.2 29.9 221.3 27.2 178.1 min) Melt Flow Ratio (I₂₁/I₂) 60 42.5 49 109 53 59 Stress Exponent 1.64 1.45 1.55 1.97 1.47 1.68 Melt Flow Ratio (I₁₀/I₂) 13.00 9.87 11 21 14 13.6 Branch Frequency-FTIR Branch Freq/1000C 23.5 25.1 23.1 13.2 13.1 7.8 Comonomer 1-octene 1-octene 1-octene 1-octene 1-octene 1-octene Comonomer Content 4.70 5 4.60 2.6 2.6 1.60 (mole %) Comonomer Content 16.5 17.4 16.2 9.8 9.7 6.0 (weight %) Internal Unsat/100C 0.011 0.011 0.011 0.008 0.006 0.007 Side Chain 0.005 0.003 0.004 0.001 0.003 0.001 Unsat/100C Terminal Unsat/100C 0.007 0.008 0.006 0.009 0.023 0.016 GPC-Conventional M_(n) 30775 20218 35034 21735 23696 21618 M_(w) 109858 81502 106445 84028 126206 83435 M_(z) 233004 172940 220882 415029 385927 367450 Polydispersity Index 3.57 4.03 3.04 3.87 5.33 3.86 (M_(w)/M_(n))

The properties of three different polyethylene compositions which were obtained from melt blending polyethylene composition A with polyethylene composition D, B with E, and C with F are provided in Table 3 as Examples 1, 2 and 3. The materials were melt blended using a Coperion ZSK 26 co-rotating twin screw extruder with an L/D of 32:1. The extruder was fitted with an underwater pelletizer and a Gala spin dryer. The materials were co-fed to the extruder using gravimetric feeders to achieve the desired ratios of polyethylene composition A to polyethylene D (and B to E and C to F). The blends were compounded using a screw speed of 200 rpm at an output rate of 15-20 kg/hour and at a melt temperature of 225-230° C.

TABLE 3 Polyethylene Composition Properties 1 2 3 (50 wt. % PE (68 wt. % PE (75 w.t % PE Composition B/ Composition A/ Composition C/ 50 wt. % PE 32 wt. % PE 25 wt. % PE Example No. Composition E) Composition D) Composition F) Density (g/cm³) 0.9182 0.9175 0.9173 Melt Index I₂ 0.82 0.57 0.87 (g/10 min) Melt Index I₆ 4.17 3.6 4.73 (g/10 min) Melt Index I₁₀ 8.65 7.72 9.9 (g/10 min) Melt Index I₂₁ 39.7 43.4 44.9 (g/10 min) Melt Flow 48.7 76 52 Ratio (I₂₁/I₂) Stress 1.49 1.68 1.54 Exponent Melt Flow 10.6 13.54 11.3 Ratio (I₁₀/I₂) Rheological Properties Zero Shear 17150 38940 23200 Viscosity- 190° C. (Pa-s) Crossover 44.21 19.48 49.03 Frequency- 190° C. (rad/s) DRI 1.50 3.90 3.85 G′ @ G″ 62.56 138.02 103.48 500 Pa = Branch Frequency- FTIR Branch 19.3 20.5 19.3 Freq/1000 C Comonomer 1-octene Comonomer 3.9 4.1 3.9 Content (mole %) Comonomer 13.8 14.6 13.8 Content (wt. %) Internal 0.008 0.009 0.009 Unsat/100 C Side Chain 0.007 0.008 0.008 Unsat/100 C Terminal 0.016 0.008 0.009 Unsat/100 C CEF Soluble 12.44 15.74 10.56 fraction (%), ≤30° C. DSC First Melting 88.800 77.400 78.500 Peak (° C.) Second 125.4 127.8 126.8 Melting Peak (° C.) Third Melting 128 Peak (° C.) T_(m) ²-T_(m) ¹ 36.64 50.36 48.3 (Second Melting Peak (° C.) minus First Melting Peak (° C.)) Heat of 126.7 122.6 128.9 Fusion (J/g) Crystallinity 43.7 42.3 44.4 (%) GPC- Conventional M_(n) 19616 24477 33648 M_(w) 99254 116617 102277 M_(z) 275187 379399 252041 Polydispersity 5.06 4.76 3.04 Index (M_(w)/M_(n)) Mz/Mw 2.77 3.25 2.46 Hexane Extractables 0.72 0.87 0.51 (%)-Plaque

Details of the polyethylene composition components: the first polyethylene, the second polyethylene, the third polyethylene, and the fourth polyethylene are provided in Table 4. With the exception of the weight percentages, w1, w2, w3 and w4 (which are found by adjusting the de-convoluted values, w1′, w2′, w3′, and w4′ as is further discussed below) the data in Table 4 includes the mathematically de-convoluted component properties of polyethylene compositions A, B and C (which comprised the first polyethylene which was made with a single site metallocene catalyst and the second polyethylene which was made with a single site phosphinimine catalyst) as well as the mathematically de-convoluted component properties of polyethylene compositions D, E and F (which comprised the third polyethylene which was made with a single site phosphinimine catalyst and the fourth polyethylene which was made with a multi site Ziegler-Natta catalyst).

Deconvolution of Polyethylene Compositions a, B and C

High temperature GPC equipped with an online FTIR detector (GPC-FTIR) was used to measure the comonomer content as a function of molecular weight. In order to de-convolute the polyethylene compositions A, B and C (which result from the use of a SSC in R1 and R2 in parallel mode polymerization) into components, the mathematical deconvolution model described in U.S. Pat. No. 8,022,143 was used. The mathematical deconvolution of the GPC and GPC-FTIR data, the molecular weight distribution of the first polyethylene (the SSC component made in R1, considered one catalyst site) and the second polyethylene (the SSC component made in R2, considered on catalyst site) was modeled using a single Schultz Flory distribution (where the Mw/Mn was assumed to be 2; the Mn was Mw/2 and the Mz was 1.5×M_(W)) as described in U.S. Pat. No. 8,022,143. To improve the deconvolution accuracy and consistency, as a constraint, the melt index, I₂, of the modeled composition (i.e. the dual-reactor polyethylene composition A, B or C) was set and the following relationship was satisfied during the deconvolution:

Log₁₀(I ₂)=22.326528+0.003467*[Log₁₀(M_(n))]³−4.322582*Log₁₀(M_(w))−0.180061*[Log₁₀(M_(z))]²+0.026478*[Log₁₀(M_(z))]³

where the experimentally measured overall melt index (i.e. of polyethylene composition A, B or C), I₂, was used on the left side of the equation. Hence, a total of two sites (one for each SSC) were used to de-convolute polyethylene composition A, B or C. The w(i) and Mn(i), i=1 to 2, were obtained while Mw(i) and Mz(i) of each site were calculated using the above relationships using Mn(i) for each site. During the deconvolution, the overall M_(n), M_(w) and M_(z) of polyethylene composition A, B or C was calculated with the following relationships: M_(n)=1/Sum(w_(i)/M_(n)(i)), M_(w)=Sum(w_(i)×M_(w)(i)), M_(z)=Sum(w_(i)×M_(z)(i)²), where i represents the i-th component and w_(i) represents the relative weight fraction of the i-th component in the composition from the above 2-site deconvolution. The GPC-FTIR chromatograph profile was subsequently deconvoluted using the w(i) results to obtain SCB(i), i=1 to 2.

The Mn, Mw, Mz and SCB/1000C of the first and second polyethylenes made with a SSC in each of R1 and R2 were then calculated using the above relationships, with the above data of Mn(i), Mw(i), Mz(i), SCB(i) for each catalyst site.

When the polymer made with the single site catalyst in R2 was an ethylene homopolymer, as is the case in the present examples, then during the deconvolution analysis the SCB/1000C for the modeled SSC site was set as zero. If however, the polymer made by the SSC was a copolymer, then the SCB value would be determined for the SSC site using the deconvolution model presented above.

In order to calculate the melt index, I₂ of each of the first and second polyethylenes in polyethylene composition A, B, or C, the following melt index, I₂ model was used:

Log₁₀(melt index,I ₂)=22.326528+0.003467*[Log₁₀(M_(n))]³−4.322582*Log₁₀(M_(w))−0.180061*[Log₁₀(M_(z))]²+0.026478*[Log₁₀(M_(z))]³

where the M_(n), M_(w) and M_(z) were the deconvoluted values of the first or second polyethylene components present in polyethylene composition A, B or C as obtained from the results of the above GPC deconvolution.

The density of the first polyethylene which was an ethylene copolymer made using a single site catalyst in R1 was calculated using the following density model:

density of the first polyethylene made with a SSC=0.979863−0.00594808*(FTIR SCB/1000C)_(0.65)−0.000383133*[Log₁₀(M_(n))]³−0.00000577986*(M_(w)/M_(n))³+0.00557395*(M_(z)/M_(w))^(0.25)

where the M_(n), M_(w) and M_(z) were the deconvoluted values of the first polyethylene as obtained from the results of the above GPC deconvolution and the SCB/1000C was obtained from the GPC-FTIR deconvolution. The density of the second polyethylene which was an ethylene homopolymer made with a single site catalyst in R2 was determined using the same equation used above for finding the density of the first polyethylene, but with the value for the short chain branching set to zero to cancel out the corresponding term:

density of the second polyethylene made with a SSC=0.979863−0.0003831331*[Log₁₀(M_(n))]³−0.00000577986*(M_(w)/M_(n))³+0.00557395*(M_(z)/M_(w))^(0.25).

The de-convolution provided the density (d1, and d2), melt index (I₂ ¹ and I₂ ²), short chain branching (SCB1 with the SCB2 being set as zero for an ethylene homopolymer) the weight average and number average molecular weights (Mw1, Mn1, Mw2 and Mn2), and the weight fraction (w1′ and w2′) of the first and second polyethylenes The resulting deconvoluted properties as well as the relative weight percentages w1, w2 (which for the first and the second polyethylenes, respectively, are found by modifying the deconvoluted weight fractions w1′ and w2′ to match the amount of polyethylene composition A, B or C in the final melt blended polyethylene composition, as determined by the blending rules discussed further below) are provided in Table 4.

Deconvolution of Polyethylene Compositions D, E and F

In order to de-convolute the polyethylene composition D, E of F (which result from the use of a ZN catalyst in R1 and a SSC in R2 in parallel mode polymerization) into components, the mathematical deconvolution model described in U.S. Pat. No. 8,022,143 was used but with some modifications to find the properties of the Ziegler-Natta component (as made in R1) as is described further below. Here, in the mathematical deconvolution of the GPC and GPC-FTIR data, the molecular weight distribution of the third polyethylene (the SSC component made in R2, considered one catalyst site) was modeled using a single Schultz Flory distribution (where the Mw/Mn was assumed to be 2; the Mn was Mw/2 and the Mz was 1.5×Mw) as described in U.S. Pat. No. 8,022,143, while the molecular weight distribution of the fourth polyethylene which was made using a multi-site Ziegler-Natta catalyst in R1, is considered to have four catalyst sites for the sake of the model, and hence was modeled using four Shultz-Flory distributions (each of which had a Mw/Mn of 2; and where Mn was Mw/2 and Mz was 1.5×M_(W) for each site). To improve the deconvolution accuracy and consistency, as a constraint, the melt index, I₂, of the modeled composition (i.e. the dual-reactor polyethylene composition D, E or F) was set and the following relationship was satisfied during the deconvolution:

Log₁₀(I ₂)=22.326528+0.003467*[Log₁₀(M_(n))]³−4.322582*Log₁₀(M_(w))−0.180061*[Log₁₀(M_(z))]²+0.026478*[Log₁₀(M_(z))]³

where the experimentally measured overall melt index (i.e. of polyethylene composition D, E or F), I₂, was used on the left side of the equation. Hence, a total of five sites (one for the SSC, i=1; and four for the ZN, i=2 to 5) were used to de-convolute polyethylene composition D, E or F. The w(i) and M_(n)(i), i=1 to 5, were obtained while Mw(i) and Mz(i) of each site were calculated using the above relationships using Mn(i) for each site. Note that the sum of w(i), i=1 to 5, is equal to unity. During the deconvolution, the overall M_(n), M_(w) and M_(z) of polyethylene composition D, E, or F were calculated with the following relationships: M_(n)=1/Sum(w_(i)/M_(n)(i)), M_(w)=Sum(w_(i)×M_(w)(i)), M_(z)=Sum(w_(i)×M_(z)(i)²), where i represents the i-th component and w_(i) represents the relative weight fraction of the i-th component in the composition from the above 5-site deconvolution. The GPC-FTIR chromatograph profile was subsequently deconvoluted using the w(i) results to obtain the short chain branching in short chain branches per 1000 carbons (the SCB/1000C) for each site: SCB(i), i=1 to 5.

To obtain the overall characteristics of the fourth polyethylene made with the Ziegler-Natta catalyst in R1, the weight fraction, w_(i) of each of the four modeled Ziegler-Natta sites from the above overall 5-site deconvolution (i=2 to 5) was normalized first (i.e. the weight fraction w_(i) of each ZN site was divided by the total weight of the four sites for the ZN components). The overall Mn, Mw, Mz and SCB/1000C of the fourth polyethylene made with the ZN catalyst in R1 were then calculated using the above relationships, with the above data of Mn(i), Mw(i), Mz(i), SCB(i) and the newly normalized w(i) for each ZN site.

When the polymer made with the single site catalyst in R2 was an ethylene homopolymer, as is the case in the present examples, then during the deconvolution analysis the SCB/1000C for the modeled SSC site was set as zero. If however, the polymer made by the SSC was a copolymer, then the SCB value would be determined for the SSC site using the deconvolution model presented above.

In order to calculate the melt index, I₂ of each of the third and fourth polyethylenes in polyethylene composition D, E or F, the following melt index, I₂ model was used:

Log₁₀(melt index,I ₂)=22.326528+0.003467*[Log₁₀(M_(n))]³−4.322582*Log₁₀(M_(w))−0.180061*[Log₁₀(M_(z))]²+0.026478*[Log₁₀(M_(z))]³

where the M_(n), M_(w) and M_(z) were the deconvoluted values of the third or fourth polyethylene components present in polyethylene composition D, E or F, as obtained from the results of the above GPC deconvolution.

The density of the fourth polyethylene which was an ethylene copolymer made using a Ziegler-Natta catalyst was calculated using the following density model:

density of the fourth polyethylene made with a ZN catalyst=0.979863−0.00594808*(FTIR SCB/1000C)_(0.65)−0.000383133*[Log₁₀(Mn)]³−0.00000577986*(M_(w)/M_(n))³+0.00557395*(M_(z)/M_(w))^(0.25)

where the M_(n), M_(w) and M_(z) were the overall deconvoluted values of the fourth polyethylene as obtained from the results of the above GPC deconvolution and the SCB/1000C was the overall deconvoluted value of the fourth polyethylene as obtained from the results of the above GPC-FTIR deconvolution. The density of the third polyethylene which was an ethylene homopolymer made with a single site catalyst in R2 was determined using the same equation used above for finding the density of the fourth polyethylene, but with the value for the short chain branching set to zero to cancel out the corresponding term:

density of the third polyethylene made with a SSC=0.979863−0.000383133*[Log₁₀(M_(n))]³−0.00000577986*(M_(w)/M_(n))³+0.00557395*(M_(z)/M_(w))^(0.25).

The de-convolution provided the density (d3, and d4), melt index (I₂ ³ and I₂ ⁴), short chain branching (SCB3 and SCB4, with the SCB3 being set as zero for an ethylene homopolymer) the weight average and number average molecular weights (Mw3, Mn3, Mw4 and Mn4), and the weight fraction (w3′ and w4′) of the third and fourth polyethylenes The resulting deconvoluted properties as well as the relative weight percentages w3, w4 (which for the third and the fourth polyethylenes, respectively, are found by modifying the deconvoluted weight fractions w3′ and w4′ to match the amount of polyethylene composition D, E or F in the final melt blended polyethylene composition, as determined by the blending rules discussed further below) are provided in Table 4.

The following basic blending rules were used to achieve the desired polyethylene compositions comprising a first, a second, a third and a fourth polyethylene:

w1=weight percentage of the first polyethylene in the final polyethylene composition;

w2=weight percentage of the second polyethylene in the final polyethylene composition;

w3=weight percentage of the third polyethylene in the final polyethylene composition;

w4=weight percentage of the fourth polyethylene in the final polyethylene composition;

w1*=weight percentage of polyethylene composition A, B or C in the melt blend;

w2*=weight percentage of polyethylene composition D, E or F in the melt blend;

w1′=weight percentage of the first polyethylene in polyethylene composition A, B or C (i.e. the w1′ determined from the mathematical deconvolution of polyethylene composition A, B or C);

w2′=weight percentage of the second polyethylene in polyethylene composition A, B or C (i.e. the w2′ determined from the mathematical deconvolution of polyethylene composition A, B or C);

w3′=weight percentage of the third polyethylene in polyethylene composition D, E or F (i.e. the w3′ determined from the mathematical deconvolution of polyethylene composition D, E or F);

w4′=weight percentage of the fourth polyethylene in polyethylene composition D, E or F (i.e. the w4′ determined from the mathematical deconvolution of polyethylene composition D, E or F);

where,

-   -   w1+w2+w3+w4=1;     -   w1*+w2*=1;     -   w1′+w2′=1; and     -   w3′+w4′=1;

so that,

-   -   w1=w1*×w1′;     -   w2=w1*×w2′;     -   w3=w2*×w3′; and     -   w4=w2*×w4′.

TABLE 4 Polyethylene Composition Component Properties Example No. 1 2 3 Polyethylene Composition Density (g/cm³) 0.9182 0.9175 0.9173 I₂ (dg/min.) 0.82 0.57 0.87 Stress Exponent. 1.49 1.68 1.54 MFR (I₂₁/I₂) 48.7 76 52 Mn 19616 24477 33648 Mw 99254 116617 102277 Mz 275187 379399 252041 Mw/Mn 5.06 4.76 3.04 Mz/Mw 2.77 3.25 2.46 The First Polyethylene Catalyst Type 1 Single Site Catalyst Single Site Catalyst Single Site Catalyst (metallocene) (metallocene) (metallocene) weight fraction, w1 0.354 0.406 0.443 (note: w1′ = 0.708 (note: w1′ = 0.597 (note: w1′ = 0.591 from deconvolution) from deconvolution) from deconvolution) Mn1 56400 93000 79600 Mw1 112800 186000 159200 Mw1/Mn1 2 (Mw1/Mn1 < 2.3) 2 (Mw1/Mn1 < 2.3) 2 (Mw1/Mn1 < 2.3) short chain branches 35.3 34.5 38 per 1000 carbons I₂ ¹ (g/10 min.) 0.53 0.08 0.14 d1 (g/cm³) 0.8846 0.8796 0.8776 The Second Polyethylene Catalyst Type 2 Single Site Catalyst Single Site Catalyst Single Site Catalyst (phosphinimine) (phosphinimine) (phosphinimine) weight fraction, w2 0.146 0.274 0.307 (note: w2′ = 0.292 (note: w2′ = 0.403 (note: w2′ = 0.409 from deconvolution) from deconvolution) from deconvolution) Mn2 8300 18000 18600 Mw2 16600 36000 37200 Mw2/Mn2 2 (Mw2/Mn2 < 2.3) 2 (Mw2/Mn < 2.3) 2 (Mw2/Mn2 < 2.3) short chain branches 0 0 0 per 1000 carbons I₂ ² (g/10 min) 1147 46.95 41 d2 (g/cm³) 0.9629 0.9565 0.9562 The Third Polyethylene Catalyst Type 3 Single Site Catalyst Single Site Catalyst Single Site Catalyst (phosphinimine) (phosphinimine) (phosphinimine) weight fraction, w3 0.144 0.187 0.149 (note: w1′ = 0.288 (note: w1′ = 0.585 (note: w1′ = 0.595 from deconvolution) from deconvolution) from deconvolution) Mn3 10100 13500 15700 Mw3 20200 27000 31400 Mw3/Mn3 2 (Mw3/Mn3 < 2.3) 2 (Mw3/Mn3 < 2.3) 2 (Mw3/Mn3 < 2.3) short chain branches 0 0 0 per 1000 carbons I₂ ³ (g/10 min) 508 151.5 81.9 d3 (g/cm³) 0.9614 0.9590 0.9577 The Fourth Polyethylene Catalyst Type 4 ZN Catalyst ZN Catalyst ZN Catalyst weight fraction, w4 0.356 0.133 0.101 (note: w2′ = 0.712 (note: w2′ = 0.415 (note: w2′ = 0.405 from deconvolution) from deconvolution) from deconvolution) Mn4 33400 34400 37800 Mw4 172300 164000 138400 Mw4/Mn4 5.15 (Mw4/Mn4 >2.3) 4.77 (Mw4/Mn4 >2.3) 3.66 (Mw4/Mn4 >2.3) short chain branches 16.28 26.88 16.44 per 1000 carbons I₂ ⁴ (g/10 min) 0.11 0.14 0.26 d4 (g/cm³) 0.9142 0.9002 0.9132

With reference to FIG. 1, a person skilled in the art will recognize that the polyethylene compositions of Examples 1-3 have a bimodal GPC profile.

With reference to FIG. 2, a person skilled in the art will recognize that the polyethylene compositions of Example 1-3 have a partially reverse comonomer incorporation, where the comonomer incorporation first rises as molecular weight increases, and then falls as the molecular weight increases still further.

With reference to FIG. 3, a person skilled in the art will recognize that the polyethylene compositions of Examples 1-3 have a multimodal DSC profile. For Examples 1 and 2 the DSC profile is bimodal while for Example 3 the DSC profile is trimodal.

The data in Table 3, clearly shows that the polyethylene compositions of Examples 1-3 have a significant amount of material eluting at lower temperature in a crystallization elution fractionation (CEF) analysis. Examples 1, 2 and 3 each have a soluble fraction in a crystallization elution fractionation (CEF) analysis of greater than 7.5 weight percent (Example 1, is 12.4 weight percent; Example 2, is 15.7 weight percent; Example 3, is 10.6 weight percent).

A van Gurp-Palmen analysis is a means by which to study a polymer architecture (e.g. molecular weight distribution, linearity, etc.) as reflected by the polymer melt rheology. A VGP curve is simply a plot of the phase angle (δ) versus complex modulus (G*), where the two rheological parameters are obtained using the frequency sweep test in dynamic mechanical analysis (DMA). A shift of a VGP curve from a baseline curve or a decrease in the phase angles around the mid-range of complex modulus (e.g. at a G* of around 10,000 Pa) suggests changes in the polymer melt rheology resulting from changes in polymer molecular structure and may be indicative of the presence of long chain branching. Without wishing to be bound by theory, the value of the phase angle (δ) at a complex modulus (G*) of 10,000 Pa, is indicative of the presence of long chain branching in the polymers of the present disclosure.

FIG. 4 shows a plot of the phase angle (δ) vs. the complex modulus (G*) for the polyethylene compositions of Examples 1-3. FIG. 4 also shows the corresponding data for other polymeric materials. Example A is Surpass® FPs016-C, is a linear polyethylene with no long chain branching, and is commercially available from NOVA Chemicals. Example B is NOVAPOL® LF-Y320-A. NOVAPOL® LF-Y320-A is a low density polyethylene (a “LDPE”) which is made under high pressure gas phase conditions and is known to contain significant amounts of long chain branching.

As can be seen from the curves in FIG. 4, Example A, which is a linear polymer having no long chain branching has a curve with no inflexion point and a phase angle (δ) of 77.1°, at a complex modulus (G*) of 10,000 Pa. In contrast, Example B, which is a low density polyethylene having significant amounts of long chain branching, has a low phase angle (δ) of 46.4°, at a complex modulus (G*) of 10,000 Pa.

When examining the curves in FIG. 4 for Examples 1-3, a person skilled in the art will recognize that they are consistent with the presence of some degree of long chain branching. The curves for Examples 1-3 all have a phase angle (δ) at a complex modulus (G*) of 10,000 Pa of less than 75°, which represents a downward deflection of the curve from that observed for the linear polymer, Example A, and toward that observed for the polyethylene having significant amounts of long chain branching, Example B.

In a plot of the transient extension viscosity (η_(E)*(t) in Pa.s) vs time (seconds) for an ethylene polymer which is known to contain long chain branching, the average MSHI (as defined above; at time=4 to t_(f) seconds at 0.3 s⁻¹ strain rate) is believed to be related to the length and amount of long chain branches (See FIG. 5 and the examples in Table 5 below). Without wishing to be bound by theory, the larger the value for the average MSHI, the longer the length and amount of the long chain branches present.

Table 5 shows the average melt strain hardening index (MSHI) for polyethylene compositions of Examples 1-3 as well as the corresponding data for other polymeric materials. Example C is Eastman® 808P, a low density polyethylene (LDPE). Example D is ExxonMobil® LD201.48, a low density polyethylene (LDPE). Example E is DuPont® LDPE 1640, a low density polyethylene (LDPE). Example F is Novapol® LC-0522-A, a low density polyethylene (LDPE). Low density polyethylene (LDPE) which is made under high pressure gas phase conditions is well known to have relatively large amount of long chain branches and the lengths of some of the long chain branches is believed similar to that of the polymer backbone.

TABLE 5 The Average Melt Strain Hardening Index (MSHI) of the Polyethylene Compositions and Comparative Resins Average Melt Slope of Test Strain Hardening Fitting, temperature Index (time from b value of extensional 4 to t_(f) seconds (1 to 4 viscosity at 0.3 s⁻¹ seconds, Example No. (degree° C.) strain rate) 0.3 s −1) C 150 1.69 3092.5 D 150 1.65 5918 E 150 1.34 6518 F 150 1.28 6501 1 150 0.96 9128 2 150 0.93 19963 3 150 1.01 11333

It can be seen in the Table 5 that each of Examples C, D, E, and F exhibit MSHI values which are higher than 1.0. The MSHI values of the polyethylene compositions of Examples 1-3 are at or below 1.0, which is less than that observed for Examples C, D, E, and F (all substantially greater than 1.0). Hence, although the polyethylene compositions of Examples 1-3 have been shown to contain long chain branching (see FIG. 4 and the phase angle (δ) vs complex modulus (G*) data discussed above), the long chain branches, at least for Examples 1-3, are believed to be shorter long chain branches than those present in conventional LDPE polymers.

Without wishing to be bound by theory, it is believed that some degree of long chain branching may enhance the thermoformability of a polyethylene composition. During the thermoforming process, a sample exists in two phases for a semi-crystalline resin: an amorphous phase that can melt or soften well below the resin melting point and a solid phase that can remain in such a state until the resin melting point is reached. It is believed that a certain amount of long chain branching can increase the melt strength of the amorphous phase, helping the amorphous phase to maintain its integrity under the deformation stresses encountered during the thermoforming process. Meanwhile, it is believed that the mechanical strength of the solid phase is also an important consideration when the solid phase is subjected to the deformation stresses of a thermoforming process. Without wishing to be bound by theory, it is believed that if the content of the long chain branching and/or the length of the long chain branches within of a polyethylene composition is too large or too long, the long chain branching may negatively affect the mechanical strength of the solid phase of a semi-crystalline resin, leading to poorer performance of a resin in a thermoforming application. Hence, it is possible that that intermediate levels of long chain branching and/or long chain branching length observed for the polyethylene compositions of Examples 1-3 (See Table 5 and FIG. 4), relative to a LDPE, are useful for thermoforming applications.

Compression Molded Monolayer Film Samples

A laboratory scale compression molding press, Wabash G304, from Wabash MPI was used to prepare compression molded films from the polyethylene compositions of Examples 1-3 as well as from other polymeric materials.

A Nylon-6 polymer (one of the polymers used to build the screening tool) was ground using a Thomas Wiley mill, into granular form, and then dried in a vacuum oven at 90° C. under 20 mmHg of vacuum for 4 hours. Next, the nylon sample was removed from the oven and placed in a desiccator, which was sealed by applying a vacuum to the desiccator. The nylon sample was cooled for at least 1 hour in the desiccator before it was compression molded.

A metal shim was used as a mold. It was a brass shim (10 inch×10 inch), in which was carefully cut out four windows of 4 inch×4 inch to serve as the mold to be used. The thickness of the shim was about 0.018 to 0.019 inch which led to a final film thickness of approximately 0.015 inch or 15 mil. The mold was filled with a measured quantity of resin (e.g. pellets of a polyethylene composition or a nylon granular sample) and sandwiched between two polished metal plates. The measured polymer quantity used was sufficient to obtain the desired film thickness of 15 mils or 0.381 mm. For the polyolefin resins, polyester sheets (Mylar) were used on top of the metal backing plates to prevent the resin from sticking to the metal plates. For the nylon 6 resin, Teflon sheets were used to prevent sticking.

The metal shim assembly with the resin sample was loaded into the compression molding press and preheated to 200° C. in the case of polyethylene materials and polyethylene-cyclic olefin copolymer blend materials, each in the absence of applied pressure and for 4 minutes. In the case of nylon 6, the sample was loaded into the compression molding press and preheated to 260° C. in the absence of an applied pressure for four minutes. To compression mold the sample the following sequence was carried out: a) the pressure was increased to 1 ton of pressure and the pressure was maintained at 1 ton for 1 minute; b) the pressure was then increased to 2 tons of pressure, and the pressure was maintained at 2 tons for 1 minute; c) the pressure was then increased to 3 tons of pressure, and the pressure was maintained at 3 tons for 1 minute; d) the pressure was then decreased to 1 ton, and the pressure was maintained at 1 ton of pressure for 1 minute; e) next the pressure was increased to 5 tons and the pressure was maintained at 5 tons for 2 minutes; f) the pressure was then increased to 28 tons, and the pressure was maintained at 28 tons for 3 minutes; g) finally, the compression molding press was cooled to about 45° C. at a rate of about 15° C. per minute, and then the pressure was released. On completion of the forgoing compression molding cycle, the metal shim assembly was taken out of the compression molding press to provide a compression molded film (or plaque). In the case of Nylon-6, the compression molded film was stored in a desiccator until cut into a specified shape (see below).

A punch die was used on the compression molded films made as described above, to “punch” out a rectangular specimen (4 inches in length×1 inch in width) having specific dimensions, see FIG. 7, and suitable for use in high temperature tensile experiments (see below). Again, the nylon-6 film specimens were placed in a desiccator prior to testing. Each sample was conditioned at room temperature and pressure for a least 48 hours, following compression molding and prior to high temperature tensile experiments.

Area Dimensional Thermoformability Index (aDTI)

A diagram depicting the general thermoforming process and deformations which occur is shown in FIG. 6. The diagram illustrates the planar deformation and the biaxial deformation which occurs when a plastic sheet or film is subjected to thermoforming in a mold.

The presently presented method, which determines the so called “area Dimensional Thermoformability Index” (aDTI) was developed to approximate the deformations which occur during thermoforming and so serves as a laboratory scale proxy test method to assess the relative theromoformability of various resins with respect to thickness distribution uniformity or tendency of corner thinning. The proxy test employed to determine the aDTI is essentially a high temperature tensile experiment carried out on a test specimen having specific dimensions. An Instron 5965 Universal Testing Machine equipped with an oven chamber was used to carry out the tensile test. The test specimen used was a 15-mil thickness compression molded monolayer film having a length of 4 inches and width of 1 inch and prepared as described above. Once the test specimen was prepared it was marked with an ink dot at specific intervals along the mid-point of the sample's width, and along the length of the test specimen (See FIG. 7). The first position was 0.79375 cm (or 5/16″) from the middle position (i.e., the position which is 2 inches from both edges of the 4-inch long specimen). The second position was 0.79375 cm (or 5/16″) away from the above first position, and the third position was 0.79375 cm (or 5/16″) away from the above second position. Symmetrically, the other three positions, relative to the middle position, can be identified in the opposite direction on the 4-inch long test specimen. Hence, a total of seven positions were identified and the data collected for these seven positions were used for the aDTI calculation. The upper and lower gripping positions are at 1.905 cm from the top and bottom edges of the 4-inch long specimen. A person skilled in the art will recognize that a different number of symmetrically marked positions could be devised in order to change the number of data points employed for the testing (in this case, the distance between two adjacent positions would need to be adjusted accordingly). The test specimen was then mounted in the oven chamber of the Instron instrument. The pulling speed of the machine was 20 in/min (8.47 mm/sec) using a 1-kN load cell with 2.5″ grip separation. The specimen was pulled up to a 300% elongation and the test was stopped even though the specimen might have the potential for higher elongation than 300% at the test temperature. The upper limit of a 300% elongation was due to the limitation imposed by the internal height of the oven chamber. Each specimen was mounted and conditioned inside the chamber for 3 minutes at the desired temperature (e.g., 105° C.) prior to the pulling test at that temperature. Five specimens were generally used in the testing procedure to determine the aDTI value for a given polymer. Typically, the thermoforming temperature for a multilayer film containing a polyethylene copolymer lies somewhere in the range of from 80 to 110° C. (and rarely reaches up to 120° C.). Accordingly, the temperatures of 95° C., 100° C. and 105° C. were used to screen various polymers during the development of the aDTI test method. However, once it became clear that the present method of determining the aDTI worked better to distinguish resins in experiments performed at 105° C., this temperature was used for further testing. A figure illustrating the test specimen before and after the tensile test was carried out is shown in FIG. 7.

Parameters such as the thickness Dimensional Thermoformability Index (“dDTI”), the width Dimensional Thermoformability Index (“wDTI”), and the area Dimensional Thermoformability Index (“aDTI”) were calculated from the pre-deformation (represented by the dimensions at room temperature prior to the high temperature tensile test) and post-deformation dimensions of the test specimen. It was found that aDTI worked better than dDTI and wDTI (although not all of this data are included here). The aDTI is calculated in the following way. Note that for the present disclosure, and the calculations provided below, seven locations were marked at the width's mid-point along the length of the test specimen, so that n=7, but a person a skilled in the art would know that the number of locations included could be varied, i.e. that n=x points. Several test specimens were also used, usually five, so that m=5, but a person a skilled in the art would know that the number of test specimens included could be varied, i.e. that m=y specimens. The final aDTI value then, determined as shown in the calculation below, encompasses the sum of all the specimens and positions and reflects the overall change in cross-sectional area between an original unstretched state to final stretched state over each i_(th) location (n) over each j_(th) specimen (m).

Area DTI Calculation:

For the i_(th) position (i=1 to n) on each specimen and the j_(th) specimen (j=1 to m); where j is the number of specimens tested and i is the number locations for which the cross-sectional area was determined on each specimen (as marked by an ink dot):

Step 1: For each specimen, a value X_(j) (j=1 to m) is calculated as follows. This is to estimate the average change of the cross-sectional area prior to and after the tensile test for each specimen:

X _(j)=Sum[(A _(ij) −A ⁰ _(ij))/A ⁰ _(ij)]/n=Sum[(d _(ij) ×W _(ij) −d ⁰ _(ij) ×W ⁰ _(ij))/(d ⁰ _(ij) ×W ⁰ _(ij))]/n

where,

A ⁰ _(ij) =d ⁰ _(ij) ×W ⁰ _(ij)

A ⁰ _(ij) =d ⁰ _(ij) ×W ⁰ _(ij)

and where n is the number of the positions on each specimen where the dimensions (thickness and width) were measured prior to and after the tensile test; d⁰ _(ij) is the initial specimen thickness at the i^(th) position of the j^(th) specimen prior to the tensile test; W⁰ _(ij) is the initial specimen width at the i_(th) position of the j^(th) specimen prior to the tensile test; d^(ij) is the specimen thickness at the i^(th) position of the j^(th) specimen after the tensile test; W^(ij) is the specimen width at the i^(th) position of the j^(th) specimen after tensile the test; A⁰ _(ij) is the initial cross-sectional area prior to the tensile test at the i_(th) position of the j_(th) specimen; and A_(ij) is the cross-sectional area at the i_(th) position of the j_(th) specimen after the tensile test;

Step 2: For the Area DTI of the j_(th) Specimen:

Area DTI_(j)=100*Sum{ABS[X _(j)−(A _(ij) −A ⁰ _(ij))/A ⁰ _(ij))]}/n

where the absolute value is taken to ensure that the value of aDTI is positive, and where for convenience, the area DTI_(j) is reported as a multiple of 100;

Step 3: Average Area DTI from all the Specimens and all the Positions Tested for a Sample:

Area DTI=Sum (Area DTI_(j))/m

Note: Similar calculations may be completed to determine thickness Dimensional Thermoformability Index (“dDTI”) if considering only the thickness dimension, and the width Dimensional Thermoformability Index (“wDTI”) if considering only the width dimension.

Without wishing to be bound by theory, a smaller measured aDTI value, should correspond to a smaller change in the dimensions (e.g., the thickness at the corners of a film after thermoforming) of a film or sheet subjected to deformation stresses during thermoforming. Hence, a smaller aDTI value should correspond to an improved thermoformability with regard to a film's thickness distribution uniformity or its tendency to thin or lose corner thickness during a thermoforming process.

The aDTI method was validated by determining the aDTI values for polymers having known good or poor thermoformability under traditional thermoforming temperatures and conditions. For example, nylon polymers are known to be much better than traditional polyolefins in the thermoformability of multilayer films, including for example the reduction of corner thinning. Also known to persons skilled in the art, is that TOPAS™ 8007 (a cyclic olefin copolymer) may be used to improve the thermoformability of traditional polyethylenes in thermoforming applications. Accordingly, and as known to persons skilled in the art, TOPAS 8007 has been used as a component in a polymer blend with a traditional polyethylene to enhance the thermoformability of multilayer films. Conversely, HPs167-AB is a nonpolar polyethylene resin with a high melting point and high crystallinity, properties which are thought to be detrimental to the thermoformability of a nonpolar polymer.

To generate the data in FIG. 8, which plots the aDTI against three different temperatures, a polymer such as nylon 6 (commercially available from BASF as Ultramid® B40L) was used. Prior to forming the compression molded films used for the tensile testing, the nylon sample was ground into a powder. The powder was compression molded into 15-mil thick, compression-molded films (see above) and stored in a desiccator with a desiccant to prevent moisture absorption. The nylon film, so stored were used in the high temperature tensile experiments.

To establish a baseline ranking system, the calculated area DTI values for 15 mil thick, monolayer films made from a nylon polymer (e.g. nylon 6), a cyclic olefin copolymer (e.g. TOPAS 8007F), a traditional unimodal polyethylene copolymer (e.g. FP-120-C) and its melt blend with a cyclic olefin copolymer (e.g. 80 wt % FP120-C+20 wt % TOPS 8007F), and a polyethylene homopolymer (e.g. HPs167-AB), were plotted for 95° C., 100° C. and 105° C., as shown in FIG. 8. At all three of the temperatures tested, the ranking of the area DTI values, was found to be consistent with what is known from to persons skilled in the art with regard to the performance of these materials in industrial thermoforming processes (e.g. the thermoforming of the materials into multilayer film structures). Hence, as shown in FIG. 8, the aDTI values established for these resins followed what is generally known to persons skilled in the art with regard to thermoformability: Nylon-6 had a relatively low aDTI; TOPAS 8007 and its blend with a traditional unimodal polyethylene copolymer had an intermediate aDTI; the traditional unimodal polyethylene copolymer had an even higher aDTI; and the HPs167-AB had the highest aDTI. Accordingly, these resins establish some benchmark values for the aDTI parameter against which a polyethylene composition (or other resin) could be compared. FIG. 8 also shows that aDTI values have a greater difference between materials when measured at a higher temperature such as 105° C. As a result, when determining how other polymer materials would perform, relative to those plotted in FIG. 8, their aDTI values were measured at 105° C. (which is slightly lower than the upper temperature typically used for the thermoforming of a polyethylene multilayer film).

Table 6 shows the aDTI of the three polyethylene compositions of the present disclosure as well as for several other polymers for comparison purposes. In addition to TOPAS 8007F, and Nylon 6, the data in Table 6 shows the relative aDTI values for a conventional polyethylene copolymer (FP120-C, a linear low density ethylene copolymer with a density of 0.920 g/cm³ and a melt index, I₂ of about 1 g/10 min, commercially available from NOVA Chemicals), a polyethylene homopolymer (HPs167-AB, an ethylene homopolymer with a density of 0.967 g/cm³ and a melt index, I₂ of about 1 g/10 min, commercially available from NOVA Chemicals) and a blend of a traditional polyethylene copolymer with a cyclic olefin copolymer (80 wt % FP120-C+20 wt % TOPAS 8007F).

TABLE 6 Area Dimensional Thermoformability Index (aDTI) of Thermoformable Film Area DTI at Example No. 105° C. 1 (Inventive)  5.86 (50 wt % PE Composition B/ 50 wt % PE Composition E) 2 (Comparative) 26.13 (68 wt % PE Composition A/ 32 wt % PE Composition D) 3 (Comparative) 17.73 (75 wt % PE Composition C/ 25 wt % PE Composition F) Nylon 6  1.67 (Comparative) TOPAS 8007F  9.24 (Comparative) FP120-C 17.12 (Comparative) 80 wt % FP120-C + 20 12.68 wt % TOPAS 8007F (Comparative) HPs167-AB 29.80 (Comparative)

A person skilled in the art will recognize from the data provided in Table 6, that the polyethylene composition of Example 1 has an aDTI at 105° C. which is dramatically lower than the comparative traditional polyethylenes, and dramatically lower than that of Examples 2 and 3. The area DTI at 105° C. for Example 1 which has a relatively low I₂₁/I₂ (i.e. <50), a T_(m) ²−T_(m) ¹ of less than 45° C. and more than 20 wt. % of a fourth polyethylene component, was well below about 15 at about 5.9, while the area DTI at 105° C. for Examples 2 and 3 which have relatively high I₂₁/I₂ (i.e. >50), a T_(m) ²−T_(m) ¹ of greater than 45° C. and less than 20 wt % of a fourth polyethylene component, was about 26.1 and 17.7 respectively. Indeed, as shown by the data in Table 6, the polyethylene composition of Example 1, has an area DTI at 105° C. value which is approaching that measured for a nylon polymer, which is known in the prior art for its superior performance in thermoformable film applications (See for example, XiaoChuan Wang and Mini Boparai, Annual Technical Conference of the Society of Plastics Engineers, May 16-20, 2010, Orlando, Fla., USA). Accordingly, a person skilled in the art would expect the polyethylene compositions of Example 1 to perform relatively well when used in thermoforming applications.

Non-limiting embodiments of the present disclosure include the following:

Embodiment A. A thermoformable film, the film comprising a polyethylene composition comprising:

from 15 to 75 wt. % of a first polyethylene which is an ethylene copolymer, the first polyethylene having a weight average molecular weight M_(W) of from 70,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 5 to 100 short chain branches per thousand carbon atoms;

from 5 to 50 wt. % of a second polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

from 5 to 50 wt. % of a third polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(w) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and

at least 20 wt. % of a fourth polyethylene which is an ethylene copolymer or an ethylene homopolymer, the fourth polyethylene having a weight average molecular weight M_(W) of from 100,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of >2.3 and from 0 to 75 short chain branches per thousand carbon atoms; wherein

the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)), the third polyethylene (SCB_(PE-3)) and the fourth polyethylene (SCB_(PE-4));

the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)) and the third polyethylene (SCB_(PE-3));

the weight average molecular weight of the second polyethylene and the third polyethylene are less than the weight average molecular weight of the first polyethylene and the fourth polyethylene; and

the weight average molecular weight of the second polyethylene and the third polyethylene are within 20,000 units of each other; wherein,

the polyethylene composition has a density of ≥0.939 g/cm³, a Tm²−T_(m) ¹ of less than 45° C., a melt index I₂ of from 0.1 to 10 dg/min, and a melt flow ratio, I₂₁/I₂ of 55.

Embodiment B. The thermoformable film of Embodiment A wherein the polyethylene composition has an area Dimensional Thermoformability Index (aDTI) at 105° C. of less than 15.

Embodiment C. The thermoformable film of Embodiment A or B wherein the polyethylene composition has a soluble fraction in a crystallization elution fractionation (CEF) analysis of at least 7.5 weight percent.

Embodiment D. The thermoformable film of Embodiment A, B or C wherein the polyethylene composition has a soluble fraction in a crystallization elution fractionation (CEF) analysis of at least 10 weight percent.

Embodiment E. The thermoformable film of Embodiment A, B, C or D wherein the polyethylene composition has a melt flow ratio, I₂₁/I₂ of greater than 40.

Embodiment F. The thermoformable film of Embodiment A, B, C, D or E wherein the weight average molecular weight of the second polyethylene and the third polyethylene are within 15,000 units of each other.

Embodiment G. The thermoformable film of Embodiment A, B, C, D, E or F wherein the weight average molecular weight of the second polyethylene and the third polyethylene are within 10,000 units of each other.

Embodiment H. The thermoformable film of Embodiment A, B, C, D, E, F or G wherein the polyethylene composition has a melting peak temperature in a differential scanning calorimetry (DSC) analysis at above 125° C.

Embodiment I. The thermoformable film of Embodiment A, B, C, D, E, F, G or H wherein the polyethylene composition has at least two melting peaks in a differential scanning calorimetry (DSC) analysis.

Embodiment J. The thermoformable film of Embodiment A, B, C, D, E, F, G, H or I wherein the first polyethylene has from 25 to 75 short chain branches per thousand carbon atoms.

Embodiment K. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I or J wherein the second polyethylene is an ethylene homopolymer.

Embodiment L. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J or K wherein the third polyethylene is an ethylene homopolymer.

Embodiment M. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K or L wherein the fourth polyethylene is an ethylene copolymer and has from 5 to 35 short chain branches per thousand carbon atoms.

Embodiment N. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L or M wherein the first polyethylene has a weight average molecular weight, M_(W) of from 75,000 to 200,000.

Embodiment O. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M or N wherein the second polyethylene has a weight average molecular weight, M_(W) of from 12,000 to 45,000.

Embodiment P. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N or O wherein the third polyethylene has a weight average molecular weight, M_(W) of from 12,000 to 40,000.

Embodiment Q. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O or P wherein the fourth polyethylene has a weight average molecular weight, M_(W) of from 100,000 to 200,000.

Embodiment R. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P or Q wherein the first polyethylene has a density of from 0.865 to 0.916 g/cm³.

Embodiment S. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q or R wherein the second polyethylene is an ethylene homopolymer having a density of from 0.940 to 0.980 g/cm³.

Embodiment T. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R or S wherein the third polyethylene is an ethylene homopolymer having a density of from 0.940 to 0.980 g/cm³.

Embodiment U. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S or T wherein the fourth polyethylene is an ethylene copolymer having a density of from 0.880 to 0.936 g/cm³.

Embodiment V. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T or U wherein the first polyethylene is present in from 20 to 70 wt %.

Embodiment W. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U or V wherein the second polyethylene is present in from 10 to 40 wt. %.

Embodiment X. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V or W wherein the third polyethylene is present in from 10 to 40 wt. %.

Embodiment Y. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W or X wherein the fourth polyethylene is present in from 5 to 50 wt. %.

Embodiment Z. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, or Y wherein the first polyethylene has a CDBI₅₀ of at least 75 wt. %.

Embodiment AA. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y or Z wherein the fourth polyethylene is a copolymer with a CDBI₅₀ of less than 75 wt. %.

Embodiment BB. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z or AA wherein the first polyethylene is a homogeneously branched ethylene copolymer.

Embodiment CC. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA or BB wherein the fourth polyethylene is a heterogeneously branched ethylene copolymer.

Embodiment DD. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB or CC wherein the first polyethylene is a made with a single site catalyst.

Embodiment EE. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC or DD wherein the second polyethylene is made with a single site catalyst.

Embodiment FF. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD or EE wherein the third polyethylene is made with a single site catalyst.

Embodiment GG. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE or FF wherein the fourth polyethylene is made with a Ziegler-Natta catalyst.

Embodiment HH. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF or GG wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n) of from 2.3 to 8.0.

Embodiment II. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF or GG wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n) of from 2.5 to 6.5.

Embodiment JJ. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, or II wherein the polyethylene composition has a density of <0.935 g/cm³.

Embodiment KK. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH or II wherein the polyethylene composition has a density of from 0.880 to 0.932 g/cm³.

Embodiment LL. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ or KK wherein the polyethylene composition has a melt index, I₂ of from 0.1 to 3.0 dg/min.

Embodiment MM. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK or LL wherein the polyethylene composition has a M_(z)/M_(w) of less than 4.0.

Embodiment NN. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK, LL or MM wherein the polyethylene composition has a melt index ratio, I₂₁/I₂ of from greater than 40 to 100.

Embodiment 00. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK, LL or MM wherein the polyethylene composition has a melt index ratio, I₂₁/I₂ of greater than 45.

Embodiment PP. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK, LL, MM, NN or OO wherein the film is a single layer film.

Embodiment QQ. The thermoformable film of Embodiment A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK, LL, MM, NN or OO wherein the film is a multilayer film. 

What is claimed is:
 1. A thermoformable film, the film comprising a polyethylene composition comprising: from 15 to 75 wt. % of a first polyethylene which is an ethylene copolymer, the first polyethylene having a weight average molecular weight M_(W) of from 70,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 5 to 100 short chain branches per thousand carbon atoms; from 5 to 50 wt. % of a second polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and from 5 to 50 wt. % of a third polyethylene which is an ethylene copolymer or an ethylene homopolymer, the second polyethylene having a weight average molecular weight M_(W) of less than 75,000, a molecular weight distribution M_(w)/M_(n) of <2.3 and from 0 to 20 short chain branches per thousand carbon atoms; and at least 20 wt. % of a fourth polyethylene which is an ethylene copolymer or an ethylene homopolymer, the fourth polyethylene having a weight average molecular weight M_(W) of from 100,000 to 250,000, a molecular weight distribution M_(w)/M_(n) of >2.3 and from 0 to 75 short chain branches per thousand carbon atoms; wherein the number of short chain branches per thousand carbon atoms in the first polyethylene (SCB_(PE-1)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)), the third polyethylene (SCB_(PE-3)) and the fourth polyethylene (SCB_(PE-4)); the number of short chain branches per thousand carbon atoms in the fourth polyethylene (SCB_(PE-4)) is greater than the number of short chain branches per thousand carbon atoms in the second polyethylene (SCB_(PE-2)) and the third polyethylene (SCB_(PE-3)); the weight average molecular weight of the second polyethylene and the third polyethylene are less than the weight average molecular weight of the first polyethylene and the fourth polyethylene; and the weight average molecular weight of the second polyethylene and the third polyethylene are within 20,000 units of each other; wherein, the polyethylene composition has a density of ≤0.939 g/cm³, a T_(m) ²−T_(m) ¹ of less than 45° C., a melt index I₂ of from 0.1 to 10 dg/min, and a melt flow ratio, I₂₁/I₂ of ≤55.
 2. The thermoformable film of claim 1 wherein the polyethylene composition has an area Dimensional Thermoformability Index (aDTI) at 105° C. of less than
 15. 3. The thermoformable film of claim 1 wherein the polyethylene composition has a soluble fraction in a crystallization elution fractionation (CEF) analysis of at least 7.5 weight percent.
 4. The thermoformable film of claim 1 wherein the polyethylene composition has a soluble fraction in a crystallization elution fractionation (CEF) analysis of at least 10 weight percent.
 5. The thermoformable film of claim 1 wherein the polyethylene composition has a melt flow ratio, I₂₁/I₂ of greater than
 40. 6. The thermoformable film of claim 1 wherein the weight average molecular weight of the second polyethylene and the third polyethylene are within 15,000 units of each other.
 7. The thermoformable film of claim 1 wherein the weight average molecular weight of the second polyethylene and the third polyethylene are within 10,000 units of each other.
 8. The thermoformable film of claim 1 wherein the polyethylene composition has a melting peak temperature in a differential scanning calorimetry (DSC) analysis at above 125° C.
 9. The thermoformable film of claim 1 wherein the polyethylene composition has at least two melting peaks in a differential scanning calorimetry (DSC) analysis.
 10. The thermoformable film of claim 1 wherein the first polyethylene has from 25 to 75 short chain branches per thousand carbon atoms.
 11. The thermoformable film of claim 1 wherein the second polyethylene is an ethylene homopolymer.
 12. The thermoformable film of claim 1 wherein the third polyethylene is an ethylene homopolymer.
 13. The thermoformable film of claim 1 wherein the fourth polyethylene is an ethylene copolymer and has from 5 to 35 short chain branches per thousand carbon atoms.
 14. The thermoformable film of claim 1 wherein the first polyethylene has a weight average molecular weight, M_(W) of from 75,000 to 200,000.
 15. The thermoformable film of claim 1 wherein the second polyethylene has a weight average molecular weight, M_(W) of from 12,000 to 45,000.
 16. The thermoformable film of claim 1 wherein the third polyethylene has a weight average molecular weight, M_(W) of from 12,000 to 40,000.
 17. The thermoformable film of claim 1 wherein the fourth polyethylene has a weight average molecular weight, M_(W) of from 100,000 to 200,000.
 18. The thermoformable film of claim 1 wherein the first polyethylene has a density of from 0.865 to 0.916 g/cm³.
 19. The thermoformable film of claim 1 wherein the second polyethylene is an ethylene homopolymer having a density of from 0.940 to 0.980 g/cm³.
 20. The thermoformable film of claim 1 wherein the third polyethylene is an ethylene homopolymer having a density of from 0.940 to 0.980 g/cm³.
 21. The thermoformable film of claim 1 wherein the fourth polyethylene is an ethylene copolymer having a density of from 0.880 to 0.936 g/cm³.
 22. The thermoformable film of claim 1 wherein the first polyethylene is present in from 20 to 70 wt. %.
 23. The thermoformable film of claim 1 wherein the second polyethylene is present in from 10 to 40 wt. %.
 24. The thermoformable film of claim 1 wherein the third polyethylene is present in from 10 to 40 wt. %.
 25. The thermoformable film of claim 1 wherein the fourth polyethylene is present in from 20 to 60 wt. %.
 26. The thermoformable film of claim 1 wherein the first polyethylene has a CDB150 of at least 75 wt. %.
 27. The thermoformable film of claim 1 wherein the fourth polyethylene is a copolymer with a CDB150 of less than 75 wt. %.
 28. The thermoformable film of claim 1 wherein the first polyethylene is a homogeneously branched ethylene copolymer.
 29. The thermoformable film of claim 1 wherein the fourth polyethylene is a heterogeneously branched ethylene copolymer.
 30. The thermoformable film of claim 1 wherein the first polyethylene is a made with a single site catalyst.
 31. The thermoformable film of claim 1 wherein the second polyethylene is made with a single site catalyst.
 32. The thermoformable film of claim 1 wherein the third polyethylene is made with a single site catalyst.
 33. The thermoformable film of claim 1 wherein the fourth polyethylene is made with a Ziegler-Natta catalyst.
 34. The thermoformable film of claim 1 wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n) of from 2.3 to 8.0.
 35. The thermoformable film of claim 1 wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n) of from 2.5 to 6.5.
 36. The thermoformable film of claim 1 wherein the polyethylene composition has a density of <0.935 g/cm³.
 37. The thermoformable film of claim 1 wherein the polyethylene composition has a density of from 0.880 to 0.932 g/cm³.
 38. The thermoformable film of claim 1 wherein the polyethylene composition has a melt index, I₂ of from 0.1 to 3.0 dg/min.
 39. The thermoformable film of claim 1 wherein the polyethylene composition has a M_(Z)/M_(w) of less than 4.0.
 40. The thermoformable film of claim 1 wherein the polyethylene composition has a melt index ratio, I₂₁/I₂ of from greater than 40 to
 50. 41. The thermoformable film of claim 1 wherein the polyethylene composition has a melt index ratio, I₂₁/I₂ of greater than
 45. 42. The thermoformable film of claim 1 wherein the film is a single layer film.
 43. The thermoformable film of claim 1 wherein the film is a multilayer film. 